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SpaceX’s Starhopper cleared by FAA for second and final flight test as locals urged to exit homes
After a full two weeks spent waiting for an FAA permit, SpaceX CEO Elon Musk and local South Texas authorities appear to be preparing Starhopper for a second major flight test as early as Monday, August 26th.
Assuming the FAA comes through with a permit, Starhopper is scheduled to lift off no earlier than 5pm EDT (21:00 UTC) on August 26th for a flight test expected to smash the low-fidelity Starship prototype’s previously altitude record of ~20m (65 ft). Confirming initial reports from NASASpaceflight.com, Musk also stated that Starhopper’s second flight will be its last, after which the steel rocket test-bed will be converted for stationary use at SpaceX’s South Texas facilities.
Prior to Musk tweeting that Starhopper may be nearing approval for its next flight, the SpaceX CEO revealed that delays were centered around the FAA’s apparent unwillingness to permit the vehicle’s next flight. Musk specifically stated that the FAA wanted more “hazard analysis”, meaning that the US aviation administration had concerns that Starhopper could pose a serious threat to local residents in a tiny housing development known as Boca Chica Village.
Technically speaking, Boca Chica Village is just 1.5 miles (2.4 km) away from SpaceX’s Starhopper launch facilities, where the vehicle is expected to reach a maximum altitude of no more than 200m (650 ft) as early as August 26th. FAA regulations tend to be prescriptive and extremely rigid, understandable given the breadth of US aviation-related activities the agency is tasked with regulating. However, a basic back-of-the-envelope analysis of Starhopper’s 200m hop suggests that the risk to local residents – even those as few as 1.5 miles away from the test – is minuscule.
Based on Starhopper’s inaugural flight, its lone Raptor engine – producing up to 200 tons (450,000 lbf) of thrust – is not exactly capable of rapidly moving the Starship prototype. For all accounts and purposes, Starhopper is a spectacularly heavy hunk of steel with the aerodynamics of a cylindrical brick – capable of flight solely through the brute-force application of a literal rocket engine. To make it even half of the distance from its launch site to the Village, Starhopper would have to remain in controlled flight while radically deviating from its planned trajectory, all while its flight termination system (FTS) – explosives meant to destroy the vehicle in a worst-case scenario – completely fails to activate.
As evidence of the apparent lack of perceived risk to local residents, Cameron County, Texas officials distributed flyers to Village residents advising – but not requiring – those choosing to remain at their homes during the test to go outside during Starhopper’s next flight. This is recommended to avoid flying glass in the event that the vehicle explodes, potentially shattering windows with the shockwave that could result, but clearly demonstrates the fact that county officials believe there is a near-zero chance of Starhopper actually impacting anywhere near the houses.
Ultimately, Starhopper’s limited flight tests clearly pose little to no actual risk to residents, but this chapter does raise a far more significant question: what happens once Starship Mk1 is ready and the flight tests SpaceX is pursuing involve distances and heights on the order of several, tens, or hundreds of kilometers? For now, answers will have to wait til a later date.
A Hop and a skip into retirement
Aside from the delays and apparent lack of consensus on the safety of Starhopper’s minor hop tests, Musk confirmed that the prototype’s second test flight ever will likely be its last, providing some interesting insight into SpaceX’s next steps. Most notably, the fact that SpaceX is willing and ready to fully retire Starhopper after such a limited test series serves as a fairly confident statement that orbital-class Starship Mk1 (Texas) and Mk2 (Florida) prototypes are extremely close to flight-readiness.
Roughly a month ago, Musk tweeted that those Starship prototypes could be ready for their first flights as early as mid-September to mid-October, “2 to 3 months” from mid-July. In additional comments made on August 20th, Musk stated that his planned Starship presentation would be delayed in light of Starhopper’s own delays, and is now instead expected to occur around a major Starship Mk1 integration milestone in “mid September”.
As previously discussed on Teslarati, Starhopper’s brief service life is entirely unsurprising, delayed by issues with Raptor engines to the point that SpaceX’s far more valuable Starship prototypes – having made relentless progress – are already nearing completion. Once those Starships are ready for almost any kind of integrated testing, Starhopper will be made entirely and immediately redundant.
“According to Musk, either or both of those orbital-class prototypes could be ready for their inaugural flight tests as early as mid-September, perhaps just 1-2 months from now. Given that Starships Mk1 and Mk2 are significantly higher fidelity than Starhopper, the ungainly testbed will likely become redundant the moment that its successors are ready for flight. In other words, Starhopper is fast approaching the end of its useful life, and SpaceX’s fight for a 200m hop-test permit could ultimately be a waste of time, effort, and money if said permit doesn’t also cover Starship Mk1.”
Teslarati.com, August 20th, 2019
On another positive note, CEO Elon Musk says that Starhopper won’t be ‘retired’ to the scrapyard and will instead be lightly modified to serve as an in-situ test stand for Raptor engines, a useful addition once SpaceX South Texas moves on to multi-engine Starship and Super Heavy testing.
With any luck, SpaceX will attempt to livestream Starhopper’s second attempted flight. Stay tuned for updates on the 5pm EDT, August 26th test.
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United Airlines CEO Scott Kirby said that SpaceX’s Starlink satellite internet is its leading competitive advantage in the U.S. airline industry. However, in recent comments, while he described the service as “the biggest competitive advantage” the carrier currently holds, he also acknowledged that the edge is temporary.
“…everybody eventually is going to have high-speed low earth orbit internet connectivity. It’s going to be a must-have. We are going to have a few years of being the only airline that has it at scale, and that’s our mission,” Kirby said. Until everyone has it, United aims to capitalize on its head start by converting trial users into long-term loyal customers.
🚨 United CEO Scott Kirby calls Starlink “the biggest competitive advantage,” but says it’s temporary.
“I think it’s the biggest competitive advantage. And it’s temporary. Like it’s not, everybody eventually is going to have high speed low earth orbit internet connectivity. It’s going to be a must-have. But we are going to have a few years of being the only airline that has it at scale, and that’s our mission.”
“I think we’re going to convince customers that United is the best airline and we’re going to get customers to switch their loyalty, to get our credit card, switch their loyalty to United. Not because of Starlink. They’re going to try us for Starlink and they’re going to stay with all the other technology, and everything else is better, and the technology in particular is so much better than technology other, and it’s accelerating because we’ve got the right tech stack, and because we’re like, our gap is getting wider and wider with our technology every day.”
Next: LAX becomes United’s first 100% Starlink hub in the first half of next year, and the United app will show your Starlink odds for each flight. https://t.co/hToyFWaWj7
— TESLARATI (@Teslarati) October 27, 2026
United has moved faster than its rivals on Starlink installations. As of mid-to-late October 2026, the system was on roughly 43 percent of its fleet, with plans to reach 61 percent by year-end, 87 percent by June 2027, and full fleet coverage by the end of next year.
The airline already operates more Starlink-equipped flights than the rest of the U.S. industry combined. Los Angeles International Airport is scheduled to become United’s first 100 percent Starlink hub in the first half of 2027, and the carrier’s app will display the likelihood that any given flight has the service.
Kirby has pointed to early evidence that the offering influences booking decisions. Some passengers loyal to other airlines are already switching flights for Starlink connectivity, something the airline, along with American Airlines, has tried to leverage against competing airlines. Both companies used status-match programs, and some of those customers are pursuing company-specific credit cards, which signals an intent to stay.
Once onboard, these customers encounter the airline’s broader investments in aircraft, larger seat-back screens, oversized bins, connection tools, and a mobile app that Kirby says outperforms competitors. Wi-Fi satisfaction scores on Starlink-equipped planes have been reported to be nearly double those on aircraft with other systems.
Competitors are moving slowly to do the same. Southwest Airlines began installations in 2025 and expects to complete them soon. Delta is pursuing Amazon’s Leo system, while American expects to start Starlink work in early 2027 and has not yet detailed regional-fleet plans. This timeline gap gives United a multi-year window in which it remains the only major U.S. carrier offering Starlink at scale.
Kirby has framed the strategy as pressing that advantage while simultaneously widening gaps in other technology areas so that customers who try United for the Wi-Fi remain for the overall experience.
The approach reflects a calculated bet that superior in-flight connectivity can accelerate share gains and support longer-term financial targets, including a 10 percent pre-tax margin goal.
High-speed internet is particularly valued by premium and business travelers who can work or stream reliably. As low-Earth-orbit service becomes ubiquitous, the temporary nature of the pure connectivity edge means United’s retention will depend on whether its other product and operational improvements keep pace.
Tesla Cybercab skips the traditional paint shop entirely, marking an unorthodox process for coloring the fully autonomous vehicle. However, the decision was a smart one, as it slashed factory costs, floor space utilization, and complexity, since Tesla relied on specialized alloys and in-mold coloring.
Munro Live was given the opportunity to do a factory walkthrough with Tesla Vice President of Vehicle Engineering Lars Moravy, who explained and detailed how Cybercab production at Giga Texas eliminates one of the automotive manufacturing industry’s most expensive and space-hungry elements.
A conventional paint line can cost hundreds of millions of dollars and require a million man-hours to build. Moravy framed the choice around Tesla’s core rule: “Question the requirements: why do you need paint?”
🚨 Super cool quote from the Cybercab breakdown on the decision to avoid traditional paint:
“One of the most expensive parts of the factory is a paint line… a few hundred million dollars, a million man hours to build one… rule number one at Tesla, question the requirements. Why do you need paint?… the alloys we use in the castings… don’t oxidize and reduce strength over time.” -@larsmoravy
Model Y and Cybertruck bodies are fully coated and painted. On Cybercab, only the side pieces get the anti-corrosion dip coat, and there’s no paint shop at all, which helps cut factory floor space per car by about 50%.
— TESLARATI (@Teslarati) October 26, 2026
The structural answer lies in material selection. The aluminum alloys used in Cybercab’s front and rear castings do not oxidize and lose strength over time, the way many common automotive aluminum alloys do. Only the side modules, built around hot-stamped boron-steel door rings, receive an anti-corrosion e-coat, or dip coat. Front and rear modules skip coating altogether.
Model Y and Model 3 bodies, by contrast, are fully coated and painted.
Exterior colors come from the plastics shop, which Tesla engineers described as “our paint shop” for the Cybercab. Body panels are produced via reaction injection molding, referred to as RIM. Color is then mixed into a polyurethane resin at the mix head immediately before injection, so the panel emerges already colored with a Class-A surface.
Robots trim overflow to control sink marks and flow lines. The process avoids conventional spray-paint defects like orange peel and paint bleed. Scratches can still be repaired with compatible coatings that behave “basically like paint.” Because color is integral rather than a surface layer, shallow scratches do not expose a contrasting undercoat.
The secret behind Tesla’s Cybercab Gold goes well beyond just the color
Tesla has also explored related approaches, including in-mold lamination and painted films on stamped panels.
The manufacturing payoff is substantial because removing the paint shop, combined with the “unboxed” modular process that builds and tests front, rear, side, and center modules in parallel before a short final assembly, cuts factory floor space per vehicle by about 50 percent.
Final assembly itself uses only about 25 automated stations, far fewer than the typical Model Y line, and the overall line runs at about 78 percent automation, Moravy said. The approach also eliminates volatile organic compound emissions associated with traditional spray painting for these panels and shortens the coloring cycle from hours to minutes.
Cybercab’s paint strategy is clearly less about aesthetics than about systematically deleting capital-intensive, energy-heavy, and space-consuming steps once material science and process design make them unnecessary. It is a concrete example of Tesla applying first-principles questioning to one of the auto industry’s most entrenched factory requirements.
Investor's Corner
Tesla has a Cybercab problem nobody saw coming
Tesla’s Cybercab line now builds robotaxis faster than Tesla can deploy them, Lars Moravy says.
Tesla’s Cybercab line in Texas can now build the two seat robotaxi faster than the company can put it into service, according to Lars Moravy, Tesla’s Vice President of Vehicle Engineering. “We don’t run every day because the line can run so fast. It’s currently outpacing our deployments,” Moravy said in a new Cybercab deep dive from Munro Live. “So, it’s a bit of a race right now. Who’s going to go faster? Right now the manufacturing line’s ahead.”
Tesla’s official Robotaxi account shared a Cybercab analysis video on X on Monday, calling it a “Cybercab engineering deep dive.” Moravy’s comments go further than what he told analysts on the Q3 earnings call last week, when he said the Cybercab line’s listed capacity of more than 125,000 units a year undersells what it can actually run.
The tour shows where that speed comes from. Tesla’s unboxed process splits the Cybercab into front, rear, side and center modules that are built and tested on their own before they meet on a short final line. That final line has just 25 fully automated stations, which Tesla’s team estimated is a fifth to a tenth of what a Model Y needs. The full line is about 78% automated, the framing line is already at 100%, and the layout uses roughly 50% less floor space per vehicle. The stated goal is “100% automation in 10 second cycle time,” or one finished Cybercab every 10 seconds.
Tesla also deleted the paint shop. Only the side modules are coated, and the exterior panels get their color inside the molding machine. Engineers said the car is designed to run at least 500,000 miles, which matters for a vehicle that will spend most of its day carrying riders.
The battery got the same treatment. The Cybercab uses an 88S6P pack of 4680 cells in a steel enclosure, a first for Tesla, with each module potted separately so a single failed module can be swapped instead of the whole pack. Wireless battery management boards replace a wiring harness, and new contactors are fast enough to drop the pyro fuse entirely. Tesla’s battery director graded the pack an A minus, compared with a D for the Model Y structural pack and a B minus for Cybertruck. Up front, the drive unit runs an 11:1 gear ratio versus roughly 9:1 on most Teslas, since the Cybercab does not need a high top speed.
Cybercab engineering deep dive — Robotaxi (@robotaxi) October 26, 2026
The deployment side is now the bottleneck Moravy described. Tesla had more than 50 Cybercabs working the Formula 1 weekend in Austin, and Texas records show 463 Cybercabs registered. Tesla said on its earnings call that Cybercab service will launch in Dallas next month, and Moravy said the company is aiming to get Cybercabs to customers by the end of 2026. Every unit built so far has gone into Tesla’s own fleet since the line moved into volume production in April.
Munro Live also asked when it could get a Cybercab to tear down. Tesla’s answer: “Not yet.”
Starlink is ‘biggest competitive advantage,’ but it’s temporary, United CEO says
Tesla Cybercab’s unorthodox paint process explained
