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SpaceX stacking two Starships at once for the first time in ten months

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As of late November, SpaceX has begun stacking two Starship prototypes simultaneously for the first time in ten months.

Known as Starship S21 and S22, SpaceX began stacking the latter prototype inside Starbase’s ‘midbay’ in mid-October – the first Starship assembly work seen in more than two and a half months. For about half a year, SpaceX has been significantly more focused on Super Heavy production as it works to thoroughly test a booster for the first time. In the interim, the assembly of Starships – which already have an impressive history of ground and flight tests – slowed to a halt, though the production of Starship parts did not.

SpaceX builds Starships by forming structures and rings out of rolls, sheets, and billets of steel. For noses, domes, and header tanks, laser or waterjet-cut steel ‘gores’ (a bit like pizza slices) are welded together. Rolls of sheet metal are unspooled, cut into sections, and welded into individual rings that are then stacked on top of each other and robotically welded together around their circumference. Those ring sections – 9m (30 ft) wide and ranging from 2-4 rings tall (3.6-7.3m or 12-24 ft) – are then outfitted with stiffener rings and stringers to add rigidity and strength.

A field of various Starship and Super Heavy rings, December 6th, 2021. (NASASpaceflight – bocachicagal)

Once that basic structure is complete, parts are cut out or welded on to create structural supports, pass-throughs, and mounts for avionics (batteries, wiring, power, comms) hardware, plumbing, mechanical systems, and more. In the case of ships, robotic arms also weld on thousand of studs that eventually become anchors for heat shield tiles. At some point, certain partially-finished ring sections are ‘sleeved’ around tank domes, of which Starship and Super Heavy both have three. Finally, at some point in the early ‘life’ of a Starship or Super Heavy, SpaceX begins assembling the actual vehicle out of that collection of different sections. While weeks or even months of work always precede that milestone, the first stack is still the point at which SpaceX decides to turn those parts into an actual vehicle – never a guarantee, no matter how far along those parts appear to be.

The roughly three-week journey of Starship S22’s forward dome section from the start of heat shield installation to the day before the section joined the rest of Ship 22’s tank stack. (NASASpaceflight – bocachicagal)

That’s where Starship S21 and Starship S22 found themselves around October 17th and November 21st. Six weeks later, now side by side in Starbase’s midbay, Ship 21’s tank section is fully stacked and Ship 22’s tank section is close to two-thirds complete. Ship 22’s nose assembly – a nosecone and section of four rings – is still in two pieces, while Ship 21’s nose is fully integrated – heat shield included.

Ship 21’s nose is nearly complete but Ship 22’s nose (bottom left) isn’t far behind. (NASASpaceflight – bocachicagal)

In the very near future, Starship S21’s tank section will be rolled from midbay to high bay for nose installation and Starship S22’s tank section will be topped off with its engine section and leg skirt. Perhaps as early as January, both ships could be fully stacked and more or less waiting in line for qualification testing ahead of Starship’s first few orbital launch attempts. Meanwhile, SpaceX is simultaneously preparing sections of Starship S23 and Super Heavy boosters B6 and B7 for possible assembly late this year or early next.

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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SpaceX nails “Lucky 13” astronaut launch, leaning into Tesla tradition and superstition

SpaceX launched Crew-13 astronauts to the ISS Thursday, setting up a record fast Dragon docking.

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Crew Dragon sits atop Falcon 9 at sunrise on Cape Canaveral's pad 40, less than a day before four astronauts are set to launch to the ISS. (Credit: SpaceX)

SpaceX launched NASA’s Crew-13 mission to the International Space Station on Thursday morning, getting four astronauts to orbit despite a forecast of thunderstorms and gusty winds that had threatened to push the flight to Friday.

Falcon 9 lifted off from Space Launch Complex 40 at Cape Canaveral Space Force Station at 11:10 a.m. ET carrying Dragon Grace, NASA confirmed. On board are NASA commander Jessica Watkins, NASA pilot Luke Delaney, Canadian Space Agency astronaut Joshua Kutryk and Roscosmos cosmonaut Sergey Teteryatnikov. The first stage booster, B1101, landed at Landing Zone 40 beside the pad on its third flight after previously supporting Crew-12 and a Starlink mission.

It was the first spaceflight for Delaney, Kutryk and Teteryatnikov. Watkins, who flew on Crew-4 in 2022, became the first NASA astronaut to launch aboard a Crew Dragon twice.

Before launch, the crew rode to the pad in Teslas, a tradition on NASA’s SpaceX crew flights since 2020. This time the cars carried specialty plates reading “Lucky 13.” Watkins said the mission patch leans into the number on purpose, as a nod to Apollo 13 and the resilience of that crew.

Grace is now on a short trip to the station. Docking at the forward port of the Harmony module is scheduled for about 7 p.m. ET, roughly 7 hours and 50 minutes after liftoff, which Space.com notes would be the fastest Crew Dragon transit to the ISS yet. Most Dragon flights take around 15 to 24 hours to catch the station. Hatch opening is planned for 8:25 p.m. ET.

The launch came more than two weeks later than originally planned. An oxidizer leak was found in Grace’s propulsion system in August, and NASA and SpaceX added time for tests. That pushed back the return of Crew-12, which has been aboard the station since February and is now set to splash down off Southern California next week. Crew-13 is expected to stay about six months.

SpaceX rescue mission for stranded ISS astronauts nears end — Here’s when they’ll return home

SpaceX already holds NASA orders for crew rotations through Crew-17, while Boeing is preparing an uncrewed Starliner flight to the station as early as December.

Crew-13 was only the first of three SpaceX launches planned for Thursday, as Teslarati previewed on Wednesday. A Falcon 9 launched its Transporter-18 mission from California today, where Google will be launching its first orbital artificial intelligence (AI) test satellite. Meanwhile, Falcon Heavy is set to launch the classified NROL-97 mission for the National Reconnaissance Office from Launch Complex 39A at 11:53 p.m. ET. Its two side boosters will return to Landing Zones 1 and 2, which means Central Florida could hear up to three sonic booms in a single day. The busy stretch follows Starship’s Flight 14 on Monday, which reached orbit for the first time.

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Tesla moves forward on Wireless Charging for vehicles

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Credit: Tesla | X

Tesla has moved its Wireless Charging efforts for its electric vehicles forward, as it had a new patent published today, one that it submitted back in March.

The patent describes a system for detecting foreign objects on the wireless charging pad under varying temperatures, aiming to mitigate any undesired results that could come from something being on top of the charging pad.

The abstract of the patent states:

“The present disclosure relates to methods and systems that can reliably detect foreign objects on a wireless charging pad under varying temperatures. In some examples, an object detector can utilize a set of inductive coils included in resonant tanks, and excite the resonant tanks using signals in a range of frequencies including or near a nominal resonant frequency of the resonant tanks. The object detector can detect a metal object based on resistance of a coil increasing and inductance of the coil decreasing. By analyzing the shifts and/or distributions in resonant frequencies and output magnitudes (e.g., output voltage peaks), the object detector can distinguish between changes of frequencies and magnitudes caused by temperature and those caused by foreign objects to accurately detect the foreign objects.”

The object detection system will utilize a set of inductive coils included in resonant tanks, and “excite the resonant tank using signals in a range of frequencies including or near a nominal resonant frequency of the tanks.” Metal can be detected by an increase in the coil’s resistance and a decrease in the coil’s inductance.

By analyzing shifts or disruptions in resonant frequencies and output magnitudes, the system can detect foreign objects. These types of safeguards need to be implemented through the normal operation of the charging pads.

Tesla says its Cybercab wireless charging efficiency is ‘well above 90%’

Tesla plans to utilize wireless charging with Cybercab and Robotaxi-enabled units to help streamline the fully autonomous experience from A to Z. The last thing the company wants to do is have any sort of small obstruction preventing the rider from experiencing Robotaxi as intended.

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Tesla launches improved Model 3 in China with V2L, new interior option

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Credit: Tesla

Tesla has launched its newest iteration of the Model 3 in China with a slew of new features, including the highly requested V2L (vehicle-to-load) feature and a new interior option.

The Model 3 now has a 16″ front touchscreen with improved resolution, a black headliner, V2L capabilities, Zen Grey interior in the Premium and Performance trims, as the White option has officially been discontinued, and 19″ Dark Nova Wheels, which are standard on the Model 3 Premium only.

The touchscreen in the U.S. version of the Model 3 is just 15.4″, so the newly upgraded screen is .6″ larger. Additionally, the Black Headliner, now standard on Model Y vehicles in the U.S., is coming to China.

Additionally, Tesla’s decision to end the white interior option has also made its way to the Asian market, as Zen Grey is the lighter color consumers can now go with. It is slightly different from the previously offered White option:

These options are available in China, Australia, and New Zealand as well, as Giga Shanghai serves those markets, bringing its mass-market vehicles to those countries in the South Pacific.

The Model 3 trims are now priced at:

  • Rear-Wheel-Drive – 235,500 yuan (~$35,000)
  • Long Range Rear-Wheel-Drive – 259,500 yuan ($38,700)
  • Long Range All-Wheel-Drive – 285,500 yuan (~$42,600)
  • Performance – 339,500 yuan (~$50,600)

These features have yet to make their way to the U.S., which might upset some buyers, but it is probably a good sign that Tesla will bring these changes to U.S. trims sometime next year. Potentially, these could come even sooner, as they could be used to stimulate demand for the year-end sales push.

Nevertheless, when things start at Giga Shanghai, they usually end up in the U.S. market. Tesla has also already started to install things like the Black Headliner and larger touchscreen in certain U.S.-built vehicles, so these things will be easy to implement across other vehicles in the lineup.

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