News
SpaceX starts stacking Starship’s first orbital-class Super Heavy booster
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.
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.
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.
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.
-
Just hours after Starship Flight 13 achieved a successful soft splashdown of its upper stage in the Indian Ocean on July 24, Elon Musk announced an ambitious next step for the company’s next launch of the rocket.
“Unless we discover problems after mission data review, SpaceX will attempt to catch the ship with the tower on [the] next flight,” the SpaceX CEO posted on X on Friday.
That “next flight” is expected to be Flight 14. The plan involves returning the Starship upper stage, commonly called the “ship,” to the Starbase launch tower in Texas and catching it mid-air using the same mechanical “chopsticks” arms that have already proven themselves with the Super Heavy booster.
Unless we discover problems after mission data review, SpaceX will attempt to catch the ship with the tower on next flight
— Elon Musk (@elonmusk) July 25, 2026
A successful catch would mark the first time an orbital-class upper stage has been recovered this way, advancing SpaceX’s goal of full and rapid reusability for the entire vehicle.
SpaceX has already demonstrated the tower-catch technique multiple times with Super Heavy. The first successful catch came on Flight 5 in October 2024, when Booster 12 was plucked from the sky by the Mechazilla arms. Subsequent flights, including those involving Boosters 14 and 15, repeated the feat. Several of those recovered boosters were later inspected, refurbished, and flown again, proving the system’s viability for quick turnaround.
Traditional reusable rockets, such as SpaceX’s own Falcon 9 or Blue Origin’s New Shepard, land on legs either on land or droneships. Rocket Lab has recovered its small Electron first stages by helicopter, but those are far lighter vehicles.
SpaceX Starship just nailed something it’s never done before
The China Academy of Launch Vehicle Technology (CALT), a subsidiary of the China Aerospace Science and Technology Corp. (CASC), completed a catch of its booster on July 10. They are the only entity besides SpaceX to attempt and complete the feat.
Flight 13 provided encouraging data. The ship executed a controlled reentry, flipped, and soft-landed intact in the ocean after deploying Starlink satellites, offering the first clear post-splashdown views of an undamaged heat shield. The Super Heavy booster, meanwhile, experienced a harder splashdown in the Gulf of Mexico.
Musk has previously stressed that ship catches would only follow multiple successful soft ocean landings to minimize risk of debris over land.
If Flight 14 succeeds, SpaceX would take a major stride toward routine, rapid reuse of both stages—critical for lowering launch costs and supporting ambitious plans for lunar and Mars missions. For now, teams are reviewing the Flight 13 data. Should everything check out, the next Starship flight could deliver one of the most spectacular recoveries in aerospace history.
In a move echoing its earlier commitment to open innovation, Tesla CEO Elon Musk announced recently that the company plans to make the design and software of its Model S and Model X fully open source.
This follows the same approach Tesla took with its original Roadster, releasing all available design, engineering, and diagnostic materials in November 2023 so that “whatever we have, you now have.”
Just as Tesla made the original Roadster design & software open source, we plan to do the same with Model S & X
— Elon Musk (@elonmusk) July 24, 2026
The Model S, introduced in 2012, was Tesla’s first mass-produced vehicle and a groundbreaking luxury electric sedan. It offered impressive range, rapid acceleration, and over-the-air software updates that redefined expectations for electric cars.
The Model X, launched in 2015, built on that foundation as a high-performance electric SUV notable for its distinctive falcon-wing doors, spacious interior, and advanced safety features. Both models served as flagships that helped establish Tesla as a leader in the EV industry and popularized long-range battery-electric vehicles.
Production of the Model S and Model X was wound down earlier in 2026, with manufacturing ending in the second quarter. Tesla redirected the Fremont factory space previously used for these vehicles toward higher-priority projects, including Optimus humanoid robots and the Cybercab autonomous vehicle.
By the time of Musk’s open-source announcement, custom orders had closed and only remaining inventory was available.
Open-sourcing the designs and software offers several clear advantages. Owners of these aging but still capable vehicles gain better access to technical documentation, diagnostic tools, and software resources, making independent repairs and modifications easier and more affordable.
Independent repair shops and third-party specialists can support the large existing fleet without relying solely on Tesla’s service network. Enthusiasts and engineers can study real-world implementations of Tesla’s battery, powertrain, and software systems, potentially accelerating broader industry progress in electric mobility.
The step aligns with Tesla’s 2014 patent pledge and its overall mission to advance sustainable transport by sharing hard-won knowledge rather than locking it behind proprietary walls.
By releasing these materials now that the models have left production, Tesla ensures continued support for its early adopters while freeing internal resources for future technologies. The open-source release of the original Roadster already enabled simulations, community projects, and deeper technical understanding.
Extending that practice to the Model S and Model X should deliver similar benefits on a larger scale, helping keep these influential vehicles relevant and repairable for years to come
Tesla flexed one incredible Robotaxi metric during the Q2 Earnings Call that skeptics have to hate to hear. The company’s platform has already driven more than 380,000 miles of unsupervised ride-hailing across several states with no notable incidents.
During the company’s Q2 Earnings Call on Wednesday, Vice President of AI, Ashok Elluswamy, said:
“First of all, I’d like to state that the Robotaxi program has been operating extremely well. Especially in terms of safety, the program has had an impeccable safety record. We have driven more than 380,000 miles of unsupervised Robotaxi, now across six cities in two different states. We have had zero notable incidents. Any reports have been of other actors impacting us when we were stationary. I like to emphasize how safe the operation has been so far. Zero notable incidents over 380,000 miles.”
Elluswamy’s claim over Robotaxi miles is a significant milestone for Tesla in the grand scheme, especially considering this is a sizeable number of miles without any incident.
0 notable incidents across over 380,000 miles traveled by Robotaxi
— Tesla (@Tesla) July 22, 2026
Tesla’s self-driving approach is much different than that of other companies. Tesla has maintained that vision is the only thing needed to have a solid and effective self-driving suite. Many self-driving companies utilize things like LiDAR, sensors, and other elements to improve performance, but Elluswamy sent a jab at those who believe it’s needed.
“Historically, the so-called experts have always claimed that you need LiDARs, radars, HD maps, and the entire kitchen sink to drive safely. Here we show that such is not true. You can have safe, comfortable, and affordable autonomy with just cameras. This record should be a huge validation of Tesla’s entire AI approach.”
The feat of accumulating this many miles without any driver behind the wheel is impressive. The thing is, Tesla is also doing this across several different locations, with varying traffic rules, pedestrian levels, weather patterns, and other important factors.
While Tesla is not ready to roll out an unsupervised platform completely, it is a slow but steady indication that the company is well on its way to figuring things out.
The company’s attitude toward expansion is slow, safe, and controlled, and despite this huge milestone, it will still be some time until we see Tesla truly unleash unsupervised rides more aggressively.
SpaceX wants to catch Starship for launch 14, Elon Musk says
Tesla to open source Model S and Model X designs and software
