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SpaceX delays Starhopper’s first flight a few days despite Raptor preburner test success

According to NASASpaceflight.com, SpaceX's Starhopper successfully completed a Raptor preburner taste on July 15th. A static fire ignition test should follow on July 16th.(NASASpaceflight - bocachicagal)

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SpaceX has (partially) ignited Starhopper’s freshly-installed Raptor engine, successfully verifying that the engine is ready for its next major test: a full ignition and static firing. Although successful, SpaceX still has some work to do before the vehicle is ready for its first untethered flight(s).

July 15th’s progress is just the latest in a several day-series of preflight tests designed to reduce the likelihood that Starhopper is destroyed over the coming days and (hopefully) weeks. If all goes planned during the awkward Starship prototype’s first foray into hover tests, SpaceX CEO Elon Musk has stated that he will provide an official presentation updating the public on the status of the company’s ever-changing next-generation rocket.

The past week or so of Starhopper preflight testing began with Raptor serial number 6 (SN06) completing the last of a series of acceptance test fires in McGregor, Texas on June 10th. Even on its own, this was a major milestone for the new SpaceX engine: Raptor SN06 was the first of the new, full-scale engines to pass the acceptance test program with flying colors. According to Musk, for the engine to complete those tests so successfully, SpaceX had to solve a challenging bug in which some sort of mechanical resonance (i.e. vibration) damaged or destroyed Raptors SN01-05.

Hours later, the engine began a short ~450 mi (720 km) journey south to Starhopper, located in Boca Chica, Texas. The engine arrived on July 11th and was fully installed on Starhopper by the following evening (July 12th), at which point SpaceX put Starhopper and Raptor through some mild but valuable thrust vector controller (TVC) tests, wiggling the car-sized engine to ensure it can accurately steer the prototype rocket.

Around two days after the above ‘wiggle’ test was successfully completed, SpaceX moved into the next stage, partially fueling Starhopper with liquid methane and oxygen propellant and helium pressurant in what is known in rocketry as a wet dress rehearsal (WDR). The (implicitly) successful WDR was capped off with a duo of what can now safely be concluded were some sort of Raptor test preceding even pre-ignition operations. Whatever the tests were, they appear to have been completed successfully.

That appears to be the case because less than 24 hours after their completion, on July 15th, SpaceX once again began loading Starhopper with propellant and pressurant for a second round of wet testing. This time around, SpaceX got right into more critical Raptor tests once enough propellant was loaded, igniting the engine’s interwoven oxygen and methane preburners.

Starhopper (technically) came alive for the third time ever on July 15th, albeit only partially. SpaceX ignited the engine’s preburners as a precursor to a full static fire, now NET July 16th. (LabPadre – YouTube livestream)

Previously discussed 24 hours ago in a Teslarati article focused on Raptor wiggles and other miscellaneous tests, Raptor is an extremely advanced rocket engine based on a cycle (i.e. how propellant is turned into thrust) known as full-flow staged combustion.

In a staged-combustion engine like Raptor, getting from the supercool liquid oxygen and methane propellant to 200+ tons of thrust is quite literally staged, meaning that the ignition doesn’t happen all at once. Rather, the preburners – essentially their own, unique combustion chambers – ignite an oxygen- or methane-rich mixture, the burning of which produces the gas and pressure that powers the turbines that bring fuel into the main combustion chamber. That fuel then ignites, producing thrust as they exit the engine’s bell-shaped nozzle.

Unintuitively, conditions inside the preburner – hidden away from view – are actually far more intense than the iconic blue, purple, and pink flame that visibly exists Raptor’s nozzle. Much like hot water will cool while traveling through pipes, the superheated gaseous propellant that Raptor ignites to produce thrust will also cool (and thus lose pressure) as it travels from Raptor’s preburner to its main combustion chamber. If the pressure produced in the preburners is too low, Raptor’s thrust will be (roughly speaking) proportionally limited at best. At worst, low pressure in the preburners can trigger a “hard start” or shutdown that could destroy the engine. According to Elon Musk, Raptor’s oxygen preburner thus has the worst of it, operating at pressures as high or higher than 800 bar (11,600 psi, 80 megapascals).”

In full-flow staged combustion (FFSC), even more complexity is added as all propellant that touches the engine must necessarily end up traveling through the main combustion chamber to eke every last ounce of thrust out of the finite propellant a rocket lifts off with. As such, FFSC engines can be about as efficient as the laws of physics allow any given chemical rocket engine to be, at the cost of exceptional complexity and brutally difficult development.

Additionally, FFSC physically requires two separate preburners and then makes things even harder by making each separate preburner (methane and oxygen) depend on each other’s operation for the engine to fully ignite. This means that no individual preburner can be used to kickstart Raptor – instead, SpaceX must somehow spin the turbopumps that feed propellant into each preburner with some separate system. This is all just to emphasize the fact that Raptor’s ignition sequence is a spectacularly complex orchestra of valves, spark plugs, sensors, and magic. This is why it’s valuable for Raptor to test its preburner system independently of an actual ignition test, at least as long as the engine is still in the development stages.

A Raptor engine is pictured here during a static fire test in McGregor, Texas. (SpaceX)

According to NASASpaceflight.com managing editor Chris Bergin, what this practically translates to is a minor Starhopper hover test delay of 1-2 days, while the static fire has also been pushed roughly 24 hours from July 15th to July 16th. If that full static fire produces lots of happy data, Starhopper could be cleared for a hover test debut attempt as early as Wednesday or Thursday (July 17/18).

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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’s next Uranium in Uranus merch is Boring Company’s weirdest tease yet

Elon Musk teased a glowing new Boring Company merch idea, complete with a Geiger counter.

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Concept rendering of Boring Company Uranium in Uranus merch tease via Grok
Concept rendering of Boring Company Uranium in Uranus merch tease via Grok

Elon Musk teased the next piece of Boring Company merchandise on X Saturday, and it is exactly as unserious as fans of the company’s product history have come to expect. “The next @boringcompany merch will put Uranium in Uranus,” Musk wrote in a thread posted early Saturday morning. He followed up by explaining that the item would glow in the dark, “because otherwise how could you find it,” and that a Geiger counter would be sold separately as “an optional strap-on.”

Musk closed the thread with a line that doubles as a mission statement for the tunneling company’s merchandise arm: “It’s not easy coming up with something that is both outrageously unsellable and yet extremely popular.”

The Boring Company has built a small but consistent side business out of novelty items that start as jokes and end up selling out. The company’s Not-a-Flamethrower raised roughly $10 million in a few days back in 2018, moving all 20,000 units it produced. Its Burnt Hair perfume, priced around $100 a bottle, sold out fast enough that scalpers were flipping units on eBay for ten times the retail price. Boring Bricks, made from tunneling spoil, followed the same playbook of teasing a product on X months before it became real.

Musk has not said what the actual item will be, only that it involves uranium and glows in the dark. Given the pattern, that vagueness is probably intentional. Past merch announcements have started as one-line jokes and taken weeks or months to turn into an actual product listing on the company’s site, and there is no guarantee this one follows through at all.

The timing lines up with a period of real momentum for the Boring Company outside of the joke merchandise. The company said last week it plans to double the number of operational stations on its Vegas Loop by the end of the year, a target tied to a hiring push for drivers and operations managers. Prufrock-5, one of the company’s tunnel boring machines, also just wrapped a test tunnel in Bastrop, Texas, and is expected to relaunch on its next assignment in November.

Whether the uranium joke turns into an actual product remains to be seen. Musk’s post did not include a price, a shipping date, or even a name for the item, which has historically meant a Boring Company website page goes up quietly, password protected, sometime before an announcement.

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News

NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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Investor's Corner

New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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