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SpaceX repairing upgraded Starship prototype after first test

Ship 24 is pictured on May 29th, two days into minor repairs. (NASASpaceflight - bocachicagal)

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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.

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SpaceX employees were still hard at work repairing Ship 24 two days later. (NASASpaceflight – bocachicagal)

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.

A pair of workers focus on finishing Ship 24’s lone ‘raceway’ cover. (NASASpaceflight – bocachicagal)

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.

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 Full Self-Driving: five things that are keeping FSD supervised

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Credit: Tesla

Tesla Full Self-Driving is really good. I have used it for over 76 percent of my driving since FSD v14 launched around this time last year, equating to about 76 percent of my miles using the suite. It’s truly the only way I prefer to travel, but admittedly I save some of the more fun drives for myself.

Even with all of the great things it has done for me, including saving me from being involved in an accident, there are still a handful of things that it needs to improve on. These issues recur from update to update, and while there have been some improvements, they still give me reasons to either soft or hard intervene.

A soft intervention means an adjustment that is needed without disengaging the suite, like manually using a turn signal to change lanes while the car still operates on FSD. What I’d consider to be a “hard intervention” is anything that requires me to disengage the suite altogether, like missing a turn or performing a maneuver I’m uncomfortable with. Of course, some hard interventions will be subjective.

Here are the five things I’d like to see Tesla really focus on through the final versions of v14 and hope to see completely improved with v15.

Speed Limit Recognition and Adjustment

There are entirely too many instances of FSD traveling at a speed that is just totally outrageous. While some of these events can occur on Hurry Mode, I’ve even had issues with it on Standard from time to time, and despite wanting more aggressive maneuvers or a slight bit of urgency, I don’t want to worry about getting a ticket while doing it.

The two areas I notice it the most are in school zones and on local roads. When a Speed Limit changes from 45 to 35, FSD does not always slow down in a way that would appease local law enforcement. On Hurry, 52-55 is pretty standard for a rate of travel in a 45 MPH zone. When it changes to 35, FSD shows zero urgency to slow down to an appropriate speed.

School Zones have been a true pain point, and as recently as last week, I had an issue with it:

Realistically, most Speed Limit issues are a soft intervention, as I simply scroll into a slower Speed Profile to get the car to slow down. School Zones are a hard intervention, as they require me to completely take over and travel at the posted 15 MPH limit. Even on Sloth, it simply does not get down to a low enough speed.

Parking

Parking is one thing that has really improved over time, but there are still some pretty considerable hoops Tesla needs to jump through to get it to a point where it can be unsupervised.

Parking preferences seem to be where a lot of these issues will be resolved, as most of my complaints come from the fact that the place FSD chooses to park are usually not where I would personally choose to park. This morning, for example, when I arrived at the gym, FSD chose to park next to a vehicle that was parked with its two tires in the spot that FSD picked.

There were three spots in between that car and the nearest car, so FSD could have chosen the spot that would have given a one-spot buffer between the two vehicles. In a parking lot full of empty spots, don’t be that guy who parks next to a car.

Generally, parking performance is vastly improved from where it was a year ago; I rarely am adjusting how it pulls or backs into a spot on v14.3.10, but in earlier versions, I definitely had my problems. It’s gotten really good since, and this version has been the best in terms of parking performance. It’s more about the places FSD choose to park, and not necessarily the parking itself.

There are also no options or map data to allow you to choose a charger at a place like a grocery store if it offers charging. These are things that are a bit more complex, but they will be needed for unsupervised FSD operation.

Navigation

Navigation was always going to be on this list, simply because it is one of the most inconsistent and mind-boggling things about FSD. Even after a year of intervening, sending voice notes, and overriding decisions, FSD still tries to take me out of my neighborhood the wrong way. You cannot turn left out of my neighborhood’s main entrance and exit, only right. Navigation still prompts a left turn out of my neighborhood’s main entrance and exit, instead of going around the neighborhood and exiting where a left turn is legal.

Tesla rolled out Preferred Routes with the Summer Update, and this has resolved some of the issues. I also found my own personal workaround:

Some of the more mind-boggling things that FSD used to do with Navigation have been remedied, but it is still a frequent complaint for me and many other owners. I’d just like to see it adopt those preferred routes more frequently and maybe learn them a little faster.

Certain Highway Behaviors

Highway travel is the most consistent and perhaps FSD’s best use case. There is nothing better than having FSD handle busy highway traffic or just long, monotonous, and boring drives. I love to use it for my trips to the Flight 93 Memorial where I volunteer. When I drove manually, I chose to get a hotel and stay overnight because it’s about a 2.5 hour drive. FSD lets me make the drive, put in a volunteering shift, and drive home, without much fatigue. I have found that this is where FSD is most valuable for me, personally.

However, there are a few things FSD does on the highway that are just weird.

One thing I’ve had issues with as of late is that there will be times when I’m about a mile from my exit, the car is in the left lane and is traveling faster than the traffic in the cruising late. Instead of completing a pass and then getting over with no traffic ahead, the car will sometimes drastically and suddenly slow down, switch to the slow lane, and get behind a vehicle — all with a mile until the exit. On average, I’ll have around one minute from the time I get to my exit if it’s a mile away, because in most cases, I’m traveling somewhere around 60 MPH on the highway.

There is no reason to not complete that last pass, then get into the right lane, and have an unobstructed path to the exit. This is one of the more strange behaviors I’ve seen it do, and it really does feel like a bug. Here’s an example of it from FSD v14.3.7:

I ended up overriding the turn signal and using the accelerator to nudge the car to do what I wanted it to do. There was no reason to get in the left lane and add to the congestion in that lane.

Another thing that FSD does frequently is camps in the left lane, especially on Hurry. Cruising in the passing lane is illegal in Pennsylvania, and I know it is not a crime to do that everywhere. However, it is here, and I really wish the car was a little quicker to get over in the left lane when it’s cruising.

Here’s a pretty drastic example I had just a couple weeks back:

Recognizing Drastic Changes in Road Condition

I think anyone who has ever used FSD knows that potholes are a huge issue, but so are large bumps or sudden changes in road condition. At the intersection of Kreutz Creek Rd. and Rt. 462 in Hellam, PA the roads are nearly set up as a ramp, and going over it at a speed of over 35 MPH can send your head into the glass roof, your butt off your seat, and a brace for the sudden thud that is inevitably coming when you finally touch back down again.

You can see here I tried to change Speed Profiles quickly, but I did it a tad too late:

There are other roads in my area that should not be taken at even the posted Speed Limit because of the damage it could do to your car. Here’s another, where I disengaged FSD altogether:

The recognition of these bumps is so crucial for two main reasons: they can cause injury, and they can cause damage to the car. These are reasons why the suite is supervised and drivers should remain attentive. I could not imagine going over that bump at an excessive speed if I had back issues, or if I were older.

Potholes are rarely recognized and usually require a lead car to avoid them. I had FSD use a lead car to avoid a pretty sizeable manhole cover a few weeks back:

Tesla says that there are improvements coming for potholes, so hopefully that means these bumps will also be recognized consistently.

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SpaceX just locked up a NASA record no other U.S. spacecraft can touch

SpaceX’s Crew-13 Dragon reached the ISS in under eight hours, and NASA confirmed a record.

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SpaceX now owns every spot on the list of the five fastest trips a U.S. spacecraft has ever made to the International Space Station, and its newest entry beat the old mark by more than four hours.

Crew Dragon Grace docked to the forward port of the station’s Harmony module at 7:05 p.m. ET on October 1, just 7 hours and 55 minutes after lifting off from Space Launch Complex 40 at Cape Canaveral. NASA confirmed the milestone in a space station blog update, writing that the flight “marked the fastest launch‑to‑docking of a U.S. spacecraft in the history of the International Space Station.”

The previous U.S. record also belonged to Dragon. SpaceX’s uncrewed CRS-31 cargo mission reached the station in a little over 12 hours in November 2024. The fastest crewed trip before last week was Crew-11, which took 14 hours and 43 minutes in August 2025, according to Space.com.

A post that Elon Musk reposted on Monday filled out the rest of the ranking. Behind Crew-13, CRS-31 and Crew-11 sit Axiom’s Ax-2 mission at 15 hours and 35 minutes and NASA’s Crew-4 at 15 hours and 44 minutes. All five flew on Dragon.

SpaceX turned a heralding moment for Starship into its greatest

Crew-13 carried NASA astronauts Jessica Watkins and Luke Delaney, Canadian Space Agency astronaut Joshua Kutryk, and Roscosmos cosmonaut Sergey Teteryatnikov. NASA had projected a docking around 8 p.m. ET, as Teslarati reported the day before launch, and Dragon arrived nearly an hour early. Our launch day coverage noted that the flight was lined up to be the quickest Crew Dragon transit yet.

The speed came from timing more than hardware. SpaceX’s Julianna Scheiman said the station “was in an opportune spot in space,” which let Dragon start closing the gap almost immediately after reaching orbit. “This is close to the fastest it could be,” she added. Most Crew Dragon flights still take close to a day, using a series of Draco thruster burns to raise and phase their orbit before arrival.

Dragon’s next job at the station is a departure. NASA said Monday it is targeting 8:05 a.m. ET on Wednesday, October 7, for Crew-12 to undock, setting up a splashdown off the coast of California around 11:34 a.m. on Thursday. Clearing that port makes room for CRS-35, a cargo Dragon carrying the final set of iROSA solar arrays.

Dragon remains NASA’s only operational ride to the station while Boeing’s Starliner stays grounded, and the agency recently added Crew-15, Crew-16 and Crew-17 to SpaceX’s contract in a $946 million modification.

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Elon Musk teases TSMC as potential Terafab partner

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SpaceX Terafab rendering
SpaceX Terafab rendering

Elon Musk has acknowledged that early discussions with Taiwan Semiconductor Manufacturing Company (TSMC) could bring the company into his ambitious Terafab semiconductor project, signaling a possible partnership with the world’s leading contract chipmaker.

Musk confirmed that early talks are underway, but as of right now, they are “just discussions.” There is no confirmation of a deal nor dismissal of the possibility of one, leaving open the prospect of one of the largest advanced-chip collaborations under discussion in the U.S.

The report that speculated on potential discussions between Terafab and TSMC comes from Tim Culpan, who outlined a few ways the collaboration could operate. One is TSMC using the project as an “anchor customer” for future facilities in Texas, potentially contributing process expertise, operational know-how, or capacity while Terafab provides capital, long-term purchase commitments, or both.

Tesla and SpaceX jointly developed the Terafab project, with Intel already participating on the tech side. Elon Musk announced the project in March, and it intends to produce more than one terawatt of AI compute capacity annually once fully built.

Elon Musk’s Terafab project locks up massive new partner

Company statements place the first phase at approximately $16.8 billion in cost, with later filings pointing to a total that could reach well into the tens of billions across multiple stages.

Intel joined the effort in April 2026 and is expected to supply its 14A manufacturing process for the full-scale plant.

Musk has said existing suppliers, including Samsung and TSMC, remain important for near-term needs; Tesla already has production arrangements with Samsung for AI5 and AI6 chips, but that future demand from Optimus robots, Cybercab vehicles, and planned space-based data centers will eventually exceed what the global industry can currently deliver.

Terafab is positioned as the long-term answer to that projected shortfall, and Tesla did something similar during COVID to avoid a chip shortage. This is just a much larger-scale solution.

If the partnership were to materialize, it would add TSMC’s industry-leading strategies to a project that already combines Tesla’s and SpaceX’s capital and offtake with Intel’s process technology. For now, the only public confirmation is Musk’s brief acknowledgement that conversations are occurring.

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