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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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4 years ago

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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.

SpaceX reveals concrete details about Starship’s first orbital test flight

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.

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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.

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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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Elon Musk reveals Tesla’s next Robotaxi expansion in more ways than one

Tesla Robotaxi is growing in more ways than one. Tesla wants to expand and hopes to reach half the U.S. population by the end of the year.

Published

16 hours ago

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July 24, 2025

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Credit: Tesla

Tesla CEO Elon Musk revealed the company’s plans for its next expansion of the Robotaxi in terms of both the geofence in Austin and the platform overall, as it looks to move to new areas outside of Texas.

Tesla launched the Robotaxi platform last month on June 22, and has since expanded both the pool of users and the area that the driverless Model Y vehicles can travel within.

The first expansion of the geofence caught the attention of nearly everyone and became a huge headline as Tesla picked a very interesting shape for the new geofence, resembling male reproductive parts.

The next expansion will likely absolve this shape. Musk revealed last night that the new geofence will be “well in excess of what competitors are doing,” and it could happen “hopefully in a week or two.”

Musk’s full quote regarding the expansion of the geofence and the timing was:

“As some may have noted, we have already expanded our service area in Austin. It’s bigger and longer, and it’s going to get even bigger and longer. We are expecting to greatly increase the service area to well in excess of what competitors are doing, hopefully in a week or two.”

The expansion will not stop there, either. As Tesla has operated the Robotaxi platform in Austin for the past month, it has been working with regulators in other areas, like California, Arizona, Nevada, and Florida, to get the driverless ride-hailing system activated in more U.S. states.

Tesla confirmed that they are in talks with each of these states regarding the potential expansion of Robotaxi.

Musk added:

“As we get the approvals and prove out safety, we will be launching the autonomous ride-hailing across most of the country. I think we will probably have autonomous ride-hailing in probably half the population of the US by the end of the year.”

We know that Tesla and Musk have been prone to aggressive and sometimes outlandish timelines regarding self-driving technology specifically. Regulatory approvals could happen by the end of the year in several areas, and working on these large metros is the best way to reach half of the U.S. population.

Tesla said its expansion of the geofence in Austin is conservative and controlled due to its obsession with safety, even admitting at one point during the Earnings Call that they are being “paranoid.” Expanding the geofence is necessary, but Tesla realizes any significant mistake by Robotaxi could take it back to square one.

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Tesla warns customers of incentive strategy on EVs as tax credit nears end

If you’re thinking of buying a Tesla, the time to order is now, the company claimed.

Published

18 hours ago

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July 24, 2025

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(Credit: Tesla)

Tesla has warned customers about its incentive strategy for qualifying electric vehicles, as the days of both the $7,500 EV tax credit for new EVs and the $4,000 credit for used EVs are coming to a close.

Both tax credits, which impact some of the vehicles in the Tesla lineup, are set to be eliminated at the end of Q3. The phase out of these consumer credits was always in the plans of the Trump Administration, but now we’re in the final quarter of their existence.

As a result, EV companies are scrambling to see how they can reduce costs or make their vehicles more affordable for customers. The $7,500 will price many consumers out of many EVs on the market, and Tesla is not immune to that.

However, Tesla has made a significant push into Q3 deliveries, rolling out numerous incentives to customers, including 0% APR on select purchases, lease deals, free upgrades on certain inventory units, and more.

The extensive list of incentives on Tesla vehicles in the quarter will not get any longer, either. During last night’s Tesla Earnings Call for the second quarter of 2025, company executives stated that their intention for these incentives was to encourage customers to place orders early in the quarter.

Tesla will only be able to apply the $7,500 credit with deliveries that occur before the end of September. Even if an order is placed before then, delivery must be completed by September 31 to receive the tax credit.

CFO Vaibhav Taneja confirmed that the incentives for the quarter are already out and encouraged customers to place an order sooner rather than later:

“Given the abrupt change, we have a limited supply of vehicles in the US this quarter. As we are already within lead times to order parts for cars, we have rolled out all our planned incentives already and will start pairing them back as we start to sell. If you are in the US and looking to buy a car, let’s roll now as we may not be able to guarantee delivery for orders placed in the later part of August and beyond.”

The loss of the incentives will impact every EV maker in the United States. Tesla has a plan moving forward, and it said last night that its affordable models would be rolled out in Q4, as introducing these cars any earlier could have detrimental effects on Model 3 and Model Y sales.

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Tesla Model Y awarded Top Safety Pick+ from IIHS

The new Model Y continues to impress with this new award.

Published

20 hours ago

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July 24, 2025

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(Credit: Tesla)

The 2025 Tesla Model Y was one of two midsize luxury SUVs to receive the Top Safety Pick+ award from the Insurance Institute for Highway Safety (IIHS).

To qualify for the IIHS’s Top Safety Pick+ or even the lower-tier Top Safety Pick label, vehicles need good ratings in the small overlap front and side crash tests, an acceptable or good rating in the pedestrian front crash prevention evaluation, and acceptable or good ratings for headlights across all trim levels.

The difference between the two labels is that an “Acceptable” rating in the moderate overlap front test will get a car the Top Safety Pick rating, but a “Good” rating in this category will win the elusive Top Safety Pick+ category.

The 2025 Model Y, codenamed “Juniper” internally by Tesla, was released in the United States earlier this year and received the top rating across each of the categories, automatically qualifying it for the Top Safety Pick+ label:

Other vehicles in Tesla’s lineup have extraordinary marks in crash testing according to other agencies, like the National Highway Traffic Safety Administration (NHTSA), but there are reasons those cars are not on the IIHS lists.

In 2024, we reported that the IIHS had evaluated some Tesla vehicles for the necessary tests to achieve these marks. Joe Young of the agency told us that the Model 3, for example, was not featured on either the Top Safety Pick or Top Safety Pick+ lists because the vehicle had several missing tests.

Here’s why the Tesla Model 3 wasn’t an IIHS Top Safety Pick+, and why it could be soon

This is not to say those other Tesla vehicles would not perform well. The Cybertruck performed better than any pickup has ever in NHTSA crash testing assessments.

The Model Y is Tesla’s most popular vehicle and was the best-selling car in the world over the past two years. Tesla’s intense focus on safety continues to show that this priority goes into every decision the company makes regarding design and engineering. This focus has continued to pay dividends as some real-world crashes save the lives of those inside the cars.

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