Connect with us

SpaceX

SpaceX builds new orbital Starship sections as Starhopper loses its engine

A tale of two Starships, April 8th. (NASASpaceflight - bocachicagal)

Published

on

Amidst the growing buzz centered around the imminent second launch of Falcon Heavy, SpaceX’s South Texas team has continued to work on Starhopper and the first orbital Starship prototype. wrapping up the first major tests of the former and making new progress on the latter’s aeroshell.

For unknown reasons, SpaceX technicians uninstalled Starhopper’s Raptor – the second full-scale engine ever built – shortly after the vehicle’s first true hop test and proceeded to package it up for shipment elsewhere, likely McGregor’s test facilities or the Hawthorne factory. Simultaneously, the third completed Raptor (SN03) was recently installed in McGregor according to photos and observations published by NASASpaceflight.com, preparing to continue to the engineering verification tests that began in February. Once those tests are complete and the engine design is modified to account for the lessons learned with Raptor SN01, SpaceX’s next step will be to begin ramping Raptor production in preparation for multi-engine Starhopper testing and – eventually – the completion of the first orbit-capable Starship prototype.

Needless to say, SpaceX is juggling a lot of interconnected projects in an effort to speed its Starship/Super Heavy (formerly BFR) development program, none of which are being discussed by the company in more than a cursory manner. What follows is thus meant to be an informed but speculative estimate of what is currently going on and what is next for BFR.

Starhopper slips the surly bonds

Over the course of the last two weeks, SpaceX has been almost continuously testing the first integrated Starship prototype, a partial-fidelity vehicle known as Starhopper. The testing primarily involved almost a dozen wet dress rehearsals (WDRs) in which the rocket was filled with some quantity of liquid oxygen and methane propellant and helium for pressurization as engineers and technicians worked through several bugs preventing Raptor from safely operating. According to CEO Elon Musk, some form of ice – potentially methane, oxygen, or even water – was forming in or around parts known as “prevalves”, likely referring to valves involved in the process of supply rocket engines with the right amount of fuel and oxidizer.

Less than 24 hours later, those valve issues were apparently solved as Starhopper’s Raptor ignited for the first time in a spectacular nighttime fireball. 48 hours after that first ignition, SpaceX once again fueled Starhopper and ignited its Raptor engine, lifting a spectacular handful of feet into the air before reaching the end of its very short tethers. According to Musk, the first Raptor ignition was completed with “all systems green”. After the second test, no additional comments were made. Less than three days later, SpaceX technicians uninstalled Starhopper’s Raptor (SN02) and shipped it somewhere offsite, indicating that it may have suffered a fault similar to the one that caused relatively minor damage to Raptor SN01 at the end of its February test campaign. Regardless, it appears that this development will keep Starhopper grounded for the indefinite future barring the imminent shipment of Raptor SN04 or the completion of SN01’s refurbishment.

The Raptor pack grows

Starhopper’s unplanned grounding ties in to the current whereabouts of SpaceX’s ever-growing collection of full-scale Raptor engines, now up to three articles with several additional engines in various stages of completion. According to photos – included in the article below – taken by a member of NASASpaceflight’s L2 forums, Raptor SN03 has been delivered to SpaceX’s McGregor, TX development facilities and installed on the same horizontal test stand that hosted Raptor SN01 and its subscale precursors. Roughly two months after SpaceX first installed and began static-firing Raptor SN01, the arrival of SN03 points to the imminent restart of the engine’s critical early-life test campaign.

Advertisement

While the exact strategy behind SpaceX’s Raptor and BFR propulsion development programs are unclear, a rough outline can be estimated from the company’s earlier Merlin engine development and general best-practices in the well-documented history of rocket propulsion. A huge amount of hot-fire testing is traditionally done with new rocket engines to work out inevitable bugs and optimize engineering as modeling, component-level tests, and subscale prototypes begin to – often imperfectly – mesh with physical reality. It’s quite possible that SpaceX is treating the >1200 seconds it static fired subscale Raptor as the bulk of that development process, with the engine as it is today representing something that the company is extremely confident in.

Regardless, the somewhat buggy behavior exhibited by the integrated Raptor and Starhopper indicate the obvious: both are fairly immature hardware still in some form of development, be it the late (Raptor) or the very earliest stages (Starhopper). By performing even more testing and continuing to optimize and gain familiarity with the hardware at hand, the fairly predictable process of development will arrive at more or less finished products.

The first finalized Raptor engine (SN01) completed a successful static fire debut on the evening of February 3rd. (SpaceX)
SpaceX technicians install Raptor SN02 on Starhopper, March 16th. (NASASpaceflight – bocachicagal)

Starship’s first orbital prototype

Last but not least, work continues on what will hopefully become the first orbit-capable Starship prototype, built in full-scale out of sheets of stainless steel that are far thinner than the metal used to construct Starhopper. This, too, is a normal process of development – as progress is made, prototypes will gradually lose an emergency cushion of performance margins, a bit like a sculptor starting with a solid block of marble and whittling it down to a work of art. Starhopper is that marble block, with inelegant, rough angles and far more material bulk than truly necessary.

As seen above, the orbital prototype – just the second in a presumably unfinished series – is already dramatically more refined. Instead of the first facade-like nose cone built for Starhopper, Starship’s nose section is being built out of smoothly tapered stainless steel panels that appear identical to those used to assemble the rocket’s growing aeroshell and tankage. As of now, there are five publicly visible Starship sections in various forms of fabrication, followed by a half-dozen or so tank dome segments waiting to be welded together as finished bulkheads.

Intriguingly, the only quasi-public official render of SpaceX’s steel Starship features visible sections very similar to those seen on the orbital prototype’s welded hull. They aren’t all visible in the render, but those that are are a distinct match to the aspect ratio of the welded sections visible in South Texas.


Extrapolating from this observation, Starship, as rendered, is comprised of approximately 16 large cylinder sections and 4-8 tapered nose sections. Based on the real orbital prototype, each large section is 9m in diameter and ~2.5m tall. Assuming Starship is 55 meters (180 ft) tall, this would translate into 22 2.5m sections, a nearly perfect fit with what is shown in the official render. Back in South Texas, SpaceX has 6 tapered sections and 7 cylinder sections in work, meaning that they would reach around 32.5m (~105 ft) – about 60% of a Starship hull – if stacked today.

If we assume that SpaceX follows Falcon procedures to build the seven-Raptor thrust structure separately (~2 sections) and excludes most of the cargo bay (~2-3 sections) on the first orbit-capable Starship, those ~13 in-work sections could be just a tapered nose cone away from the prototype’s full aeroshell. Time will tell…

Check out Teslarati’s newsletters for prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket launch and recovery processes.

Advertisement

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.

Advertisement
Comments

News

SpaceX set to launch Axiom’s mission for diabetes research on the ISS

Axiom’s Ax-4 will test CGMs & insulin stability in microgravity—potentially reshaping diabetes care for Earth & future astronauts.

Published

on

(Credit: SpaceX)

Axiom Space’s Ax-4 mission is set to launch on a SpaceX Falcon 9 rocket. Ax-4 will advance diabetes research in microgravity, marking a milestone for astronaut health.

Axiom Space’s fourth crewed mission is scheduled to launch with SpaceX on May 29 from NASA’s Kennedy Space Center in Florida. The Ax-4 mission will carry a diverse crew and a record-breaking scientific payload to the International Space Station (ISS).

The Ax-4 crew is led by Axiom’s Peggy Whitson and includes Shubhanshu Shukla from India, Sławosz Uznański from the European Space Agency, and Tibor Kapu from Hungary. The mission represents firsts for India, Hungary, and Poland, with Uznański being Poland’s first astronaut in over 40 years.

Ax-4 will conduct nearly 60 science investigations from 31 countries during its two-week ISS stay. A key focus is the “Suite Ride” initiative, a collaboration with Burjeel Holdings to study diabetes management in microgravity.

“The effort marks a significant milestone in the long-term goal of supporting future astronauts with insulin-dependent diabetes (IDDM), a condition historically deemed disqualifying for spaceflight,” Axiom noted. The mission will test Continuous Glucose Monitors (CGMs) and insulin stability to assess their performance in space.

Advertisement

Axiom explained that testing the behavior of CGMs and insulin delivery technologies in microgravity and observing circadian rhythm disruption could help diabetes experts understand how CGMs and insulin pens can improve diabetes monitoring and care in remote or underserved areas on Earth. The research could benefit diabetes management in isolated regions like oil rigs or rural areas.

The mission’s findings on insulin exposure and CGM performance could pave the way for astronauts with diabetes to safely participate in spaceflight. As Axiom and SpaceX push boundaries, Ax-4’s diabetes research underscores the potential for space-based innovations to transform healthcare on Earth and beyond.

Continue Reading

Elon Musk

EU considers SES to augment Starlink services

The EU considers funding SES to support Starlink. With MEO satellites already serving NATO, SES could be key in Europe’s space autonomy push.

Published

on

EU-ses-starlink-augment
(Credit: SES)

European satellite company SES is negotiating with the European Union (EU) and other governments to complement SpaceX’s Starlink, as Europe seeks home-grown space-based communication solutions. The talks aim to bolster regional resilience amid growing concerns over reliance on foreign providers.

In March, the European Commission contacted SES and France’s Eutelsat to assess their potential role if American-based Starlink access for Ukraine was disrupted. The European Commission proposed funding EU-based satellite operators to support Kyiv. Ukraine is considering alternatives to Starlink over concerns about Elon Musk’s reliability.

Arthur De Liedekerke of Rasmussen Global warned, “Elon Musk is, in fact, the guardian of Ukraine’s connectivity on the battlefield. And that’s a strategic vulnerability.” However, SpaceX’s Starlink constellation is leagues ahead of any competition in the EU.

“Now the discussions are much more strategic in nature. They’re much more mid-term, long-term. And what we’re seeing is all of the European governments are serious about increasing their defense spending. There are alternatives, not to completely replace Starlink, that’s not possible, but to augment and complement Starlink,” SES CEO Adel Al-Saleh told Reuters.

Advertisement

SES operates about 70 satellites, including over 20 medium Earth orbit (MEO) units at 8,000 km. The company provides high-speed internet for government, military, and underserved areas. It plans to expand its MEO fleet to 100, enhancing secure communications for NATO and the Pentagon.

“The most significant demand (for us) is European nations investing in space, much more than what they did before,” Al-Saleh said.

Competition from Starlink, Amazon’s Kuiper, and China’s SpaceSail, with their extensive low-Earth orbit constellations, underscores Europe’s push for independence.

“It is not right to say they just want to avoid Starlink or the Chinese. They want to avoid being dependent on one or two providers. They want to have flexibility,” Al-Saleh noted.

SES’s discussions reflect Europe’s strategic shift toward diversified satellite networks, balancing reliance on Starlink with regional capabilities. As governments ramp up defense spending, SES aims to play a pivotal role in complementing global providers, ensuring robust connectivity for military and civilian needs across the continent.

Advertisement
Continue Reading

News

Amazon launches Kuiper satellites; Can it rival Starlink?

With 27 satellites in orbit, Amazon kicks off its $10B plan to deliver global broadband. Can Bezos’ Kuiper take on Musk’s Starlink?

Published

on

amazon-kuiper-satellite-starlink-rival
(Credit: Amazon)

Amazon’s Project Kuiper launched its first 27 satellites on Monday, marking the start of a $10 billion effort that could compete with SpaceX’s Starlink with a global broadband internet network.

Amazon’s Kuiper satellites launched aboard a United Launch Alliance Atlas V rocket from Cape Canaveral, Florida. Project Kuiper’s recent launch is the initial step toward deploying Amazon’s 3,236 satellites for low-Earth orbit connectivity. Amazon’s satellite launch was initially set for April 9 but was delayed due to bad weather.  

Now that the Kuiper satellites have been launched, Amazon is expected to publicly confirm contact with the satellites from its mission operations center in Redmond, Washington. The company aims to start offering Kuiper services to customers later this year. Project Kuiper was unveiled in 2019 and targets consumers, businesses, and governments who need reliable internet service, similar to Starlink.

Amazon has a deadline from the U.S. Federal Communications Commission to deploy 1,618 satellites by mid-2026. Analysts suggest the company may require an extension to its Kuiper satellite deployment deadline due to the project’s year-long delay from its planned 2024 start.

United Launch Alliance could conduct up to five more Kuiper missions this year, according to ULA CEO Tory Bruno. Amazon noted in a 2020 FCC filing that Kuiper services could begin with 578 satellites, initially covering northern and southern regions.

Advertisement

Kuiper’s launch pits Amazon against SpaceX’s Starlink and telecom giants like AT&T and T-Mobile, with a focus on underserved rural areas.

“There’s an insatiable demand for the internet,” Amazon Executive Chairman Jeff Bezos told Reuters in January. “There’s room for lots of winners there. I predict Starlink will continue to be successful, and I predict Kuiper will be successful as well.”

Global interest in satellite alternatives is rising. Ukraine is exploring Starlink alternatives with the European Union (EU), driven by concerns over Elon Musk. Germany’s military, Bundeswehr, also plans its own constellation to ensure independent communications. However, like Amazon’s Kuiper Project, EU options lag behind Starlink.

Amazon’s consumer expertise and cloud computing infrastructure give Kuiper a competitive edge despite Starlink’s market lead. As Kuiper ramps up launches, its success could reshape broadband access while challenging SpaceX’s dominance in the satellite internet race.

Advertisement
Continue Reading

Trending