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SpaceX starts stacking Starship’s first orbital-class Super Heavy booster

All but hidden behind Starship SN16, SpaceX appears to have begun stacking the first flightworthy Super Heavy booster. (NASASpaceflight - bocachicagal)

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By all appearances, SpaceX has begun the process of stacking what could become the first Super Heavy booster capable of supporting orbital Starship test flights.

Known as booster number 3 (BN3), numerous sections of the 70-meter-tall (230 ft) steel rocket have been spotted at SpaceX’s Boca Chica, Texas factory over the last six or so weeks – adding up to a substantial portion of what is now expected to be the first flightworthy Super Heavy. Earlier this year, SpaceX stacked Super Heavy BN1 to its full height but late design changes effectively rendered the prototype largely irrelevant and turned it into more of a manufacturing pathfinder and source of practice than anything else.

As a result, BN1 never even left the high bay it was built in before SpaceX workers cut the booster into scrap. As of May, while a handful of parts for booster number 2 have been spotted, signs indicate that BN2 will be turned into a small test tank to qualify Super Heavy’s complex and unproven thrust dome and engine section.

That leaves Super Heavy BN3. According to NASASpaceflight.com, SpaceX has nominally assigned booster BN3 to support Starship SN20 on its inaugural space launch attempt. Just last week, SpaceX filed an application with the FCC for permission to communicate with Starship and Super Heavy during that “orbital test flight” – paperwork that included a six-month launch window scheduled to open no earlier than June 20th.

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If approved by the FCC and – far more importantly – the FAA, Starship’s first “orbital test flight” will circumnavigate three-quarters of the world in approximately 90 minutes, launching from Boca Chica and ending – if all goes well – with Starship SN20 gently splashing down near Kauai, Hawai’i. From the sparse documentation SpaceX included in the public application, it’s ambiguous if there will be an attempt to recover Super Heavy booster BN3 or if the test flight will actually be orbital, given that Starship SN20 wont complete a full orbit.

Technically speaking, although a Starship capable of safely launching from Texas to Hawai’i is almost unequivocally capable of reaching orbit, the safest possible “orbital” flight test for such a massive spacecraft would stop just shy of orbit. A guaranteed free-return reentry would make it almost impossible for Starship to reach orbit, fail to deorbit after its first ~90 minutes in space, and end up posing a risk to populated areas – like, say, the now-infamous boosters of China’s Long March 5B rocket. Regardless, it’s clear that the specifics of Starship’s first spaceflight attempt are still very much up in the air and liable to change over the next few weeks.

Super Heavy BN3’s unique common dome section was completed and flipped earlier this month. (Jack Beyer – NASASpaceflight)
(NASASpaceflight – bocachicagal)
BN3’s engine section and thrust dome have also been more or less completed. (NASASpaceflight – bocachicagal)

What isn’t up in the air is the fact that SpaceX will need to all but fully assemble and test Super Heavy booster BN3 and Starship SN20 before any potential space shot. Along those lines, SpaceX still has a huge amount of work to do. Per Twitter user Brendan Lewis’ accounting, SpaceX has at least six BN3 sections – amounting to 22 rings and two of three tank domes – either completed or awaiting integration. The process of stacking BN3 began sometime in the last 7-10 days when SpaceX joined two four-ring sections – including the booster’s common dome, likely pictured above.

Looking more like a spaghetti monster than rocket part, this is likely the first 28-engine Super Heavy fuel manifold. (NASASpaceflight – bocachicagal)
A super (heavy) sized version of the methane transfer tube already used on Starship. (NASASpaceflight – bocachicagal)

SpaceX has mostly completed BN3’s engine section, including a thrust dome with plumbing cutouts for a full 28 Raptor engines. Most recently, what looks like a Super Heavy fuel manifold appeared in Boca Chica. That manifold will attach to the end of a supersized Super Heavy transfer tube – also spotted in work – used to route methane through the liquid oxygen tank to fuel its Raptor engines. Fueling 28 large, high-performance Raptors is no mean feat and requires a rat’s nest of plumbing to feed them more than 15 metric tons (~30,000 lb) of propellant every second at full throttle.

Put simply, a majority of Super Heavy booster BN3’s hardware appears to be ready or almost ready for integration. The eight rings now stacked represent approximately 20% of the rocket’s full height, leaving another 30 or so rings – 54m (~180 ft) – to go. Given how long BN1 assembly took SpaceX, the company has its work cut out for it to fully integrate BN3 by June 20th, and the first operational Super Heavy prototype will almost certainly need to complete several major tests before being cleared for flight. As such, an inaugural space launch attempt in June or July is wildly implausible, but it’s far from out of the question that Starship and Super Heavy could be ready for their first “orbital test flight” before summer turns to fall.

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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Ferrari unveils its Luce EV, and its reception has been a disaster

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Credit: Ferrari

Ferrari unveiled its Luce EV over the weekend, and so far, its reception has been an absolute disaster, gathering negative reactions from a wide variety of people, including former executives.

The stock even took a hit on its first day of trading following the unveiling, dropping over 7 percent at one point.

Ferrari moving to EVs from its traditional V12s and mid-engine sports cars is a massive move. It was designed by Sir Jony Ive and Marc Newsom’s LoveFrom studio, which is known for design work for tech giant Apple. “Luce” means “light” in Italian, so Ferrari drew inspiration for its name from its sleek design, characterized by a smooth, sculpted body with rounded edges.

But its reception has been far from what Ferrari expected. The overall design has drawn some harsh criticism since its reveal, and it is simply stunning that such a storied company, with a rich history of beautiful, powerful cars has revealed a design that many are not a fan of.

Responses to the design were widely negative, with some saying, “Enzo is rolling in his grave,” and “This looks like a Nissan LEAF with a bad body kit.”

Former Ferrari Chairman Luca di Montezemolo said:

“If I said what I really think, I’d harm Ferrari. We’re risking the destruction of a myth, I’m very sorry about that. I hope they at least remove the Prancing Horse from that car.”

Ferrari has scaled back EV commitments in the past, primarily in response to weaker-than-expected demand for its electric powertrains.

Priced at roughly $640,000 in the U.S., it is tough to see how this car will ever truly live up to the massive expectations many had for it. It almost feels like, to a certain extent, Ferrari is looking for a way to get out of building EVs.

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Tesla unveils juicy new detail on the Roadster and hints at new unveil timeline

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A red Tesla Roadster driving around a turn
(Credit: Tesla)

Tesla unveiled a juicy new detail on the Roadster, its long-delayed supercar project, and additionally hinted at a new unveiling timeline, as it appears yet another month will pass without seeing the capabilities of the vehicle.

Vice President of Vehicle Engineering at Tesla, Lars Moravy, revealed on the Ride the Lightning podcast that the Roadster will be built at Gigafactory Texas, adding that “you’ll start to see a lot of things unfold in the next months.”

While we get a good detail on the plant of manufacture, we also get another letdown, as it appears the unveiling event will not take place in May, as CEO Elon Musk hinted during the Earnings Call.

The Roadster was first unveiled back in 2017, alongside the Semi, which entered production earlier this year. It was Tesla’s attempt at a true supercar; it would be rare, expensive, and lightning quick, among other incredible capabilities, like potentially hovering for a short period thanks to a collaboration project with SpaceX.

However, the vehicle was set to be delivered in 2020. Parts and supply chain issues due to the COVID-19 pandemic started these delays, and since then, Tesla, and specifically Musk, have wanted to push the capabilities of the Roadster to somewhere the human mind may not be able to currently comprehend.

Both Chief Designer Franz von Holzhausen and Moravy have said many things about the Roadster over the past few years, hinting that the car truly could be worth the wait. However, the continuous delays we’ve seen have undoubtedly been discouraging.

With that being said, it’s not like Tesla has been doing nothing. Instead, the company has been focusing on revamping current models, phasing out others, and working on developing the cars of the future, specifically, the Cybercab, which entered production at Giga Texas in April.

Despite the Roadster’s delays, there is still a ton of anticipation for the vehicle to be released. It will have a steering wheel, as Musk said it will be “the best of the last of the human-driven cars.”

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NASA just gave SpaceX more crew missions because Boeing can’t certify

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NASA has filed a procurement notice announcing its intent to add six post-certification missions to SpaceX’s existing Commercial Crew Transportation Capability contract. The agency said it would order up to three of those missions immediately upon adding them to the contract, with the remaining three available as needed through the end of the International Space Station’s planned operations in 2030.

The reason for the expansion is straightforward. NASA cited recently shortened ISS mission durations, technical issues and schedule delays encountered by Boeing, the allocation of missions between Boeing and SpaceX, and the ongoing technical challenges of maintaining a reliable crew transportation capability as the driving factors behind the decision. Boeing’s CST-100 Starliner has still not been certified for crewed flights, and a cargo-only Starliner mission was not included on NASA’s most recent mission manifest. With Boeing effectively sidelined for the foreseeable future, SpaceX is the only American company capable of rotating crews to the station.

SpaceX Board has set a Mars bonus for Elon Musk

The history behind this contract tells the fuller story of how SpaceX got here. NASA originally awarded SpaceX its Commercial Crew contract in 2014 for $2.6 billion. In 2022 NASA modified the contract to add five missions covering Crew-10 through Crew-14, worth $1.436 billion, bringing the total contract value at that point to $4.9 billion. The recent May 18 filing by NASA extends that runway further, with Crew-12 currently docked at the station and Crew-13 assigned and targeting a mid-September 2026 launch.

According to a report by SpaceNews, NASA stated in its filing: “It is necessary to award additional PCMs to SpaceX given the recently shortened ISS mission durations, technical issues and schedule delays encountered by Boeing, the allocation of missions between Boeing and SpaceX, NASA’s projections for when an alternative crew transportation system may become available, and the ongoing technical challenges of maintaining a reliable capability for crewed flights to ISS.”

No dollar value for the new six missions has been publicly confirmed yet, but based on the 2022 precedent of roughly $287 million per mission, the new block could represent close to $1.7 billion in additional contract value. With SpaceX simultaneously preparing Starship as NASA’s Artemis lunar lander, filing its S-1 for a June IPO, and now absorbing more ISS crew rotation work, the company’s role as the primary contractor for American human spaceflight is no longer a matter of circumstance. It is NASA policy.

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