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SpaceX wants to unleash Starhopper but longer Raptor test fires come first

SpaceX has reportedly fired a Raptor engine for more than 40 seconds, a necessary step along the path to untethered Starhopper test flights. (SpaceX & NASASpaceflight/bocachicagal)

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According to SpaceX CEO Elon Musk, the next round of Starhopper activity will focus on removing the spacecraft prototype’s tethers and performing far more substantial hop tests.

Longer tests demand that SpaceX begins expanding the known performance envelope of its full-scale Raptor engine. Towards that end, longer-duration tests would need to be done at the company’s McGregor, TX development facilities to reduce risk, tests that Musk confirmed are already well underway. A recent Raptor static fire reportedly lasted no less than 40 seconds, more than enough time for a single-engine Starhopper to significantly expand both the maximum altitude and velocity of future hop tests. In support of the upcoming Starhopper test campaign, significant construction work is also ongoing at SpaceX’s Boca Chica test and development facilities.

Starhopper awaits its return to hop testing, April 24th. (NASASpaceflight – bocachicagal)

Unleashing the Hopper

During the months of March and April, SpaceX’s South Texas team effectively completed Starhopper and put the prototype through its first real tests. The process began with tank proof tests in which Starhopper’s tanks were filled with liquid nitrogen – relatively neutral and unreactive – to safely identify and repair any leaks, while also subjecting the vehicle to cryogenic temperatures. The proof testing also put the newly installed ground systems (GSE) and vehicle-pad connection hardware through their paces before moving to Starhopper’s nominal liquid oxygen and liquid methane propellant.

Following at least half a dozen or so wet dress rehearsals (WDRs) that saw Starhopper loaded with LOx and methane, SpaceX technicians analyzed the health of the prototype and soon began live tests with a Raptor engine installed. Designed to produce no less than 2000 kN (450,000 lbf, 205 mT) of thrust at full throttle, Raptor offers more than twice the max thrust of the latest variant of the Merlin 1D engine that powers Falcon 9 and Heavy (941 kN or 212,000 lbf). In other words, a single Raptor should be more than enough to lift Starhopper off the ground 150+ tons of propellant aboard.

In the above tweets, Musk indicates that Starhopper’s next step will be untethered hop tests powered by one Raptor engine. This is further supported by confirmation that Raptor completed its longest static fire test yet on April 27th.

After several unsuccessful test attempts, Starhopper completed two static fires (<10s combined) and hopped – tethered – a handful of feet off the ground on April 3rd and 5th, three weeks after Raptor was first installed. Days later, the lone Raptor engine was removed from Starhopper and shipped back to SpaceX’s Hawthorne, CA factory or McGregor, TX testing facilities for post-test analysis and inspection. In short, SpaceX used Starhopper as a sort of ad hoc test stand for the second serial Raptor (SN02) produced, completing two major acceptance tests simultaneously.

A handful of concise tweets published by Musk in the last few days of April implicitly confirmed that the next steps for Starhopper involved untethered flights off its South Texas pad, once again powered by a single Raptor engine. As both the prospective altitudes and flight times rise for future Starhopper tests, so do the risks posed to SpaceX’s adjacent facilities and the prototype itself. To minimize those risks and progress the Raptor program as a whole, SpaceX has been extensively testing the third serial Raptor (SN03) at its McGregor facilities. Instead of a rushed test regime similar to the one that almost completely destroyed Raptor SN01 less than two weeks after testing began, SN03 is participating in a more cautious and systematic series of tests.

Technicians work inside Starhopper’s LOx tank on April 22nd. (NASASpaceflight – bocachicagal)
While almost impossible to visualize the changes from a flat perspective, several dozen trucks of dirt and concrete were delivered to Starhopper’s pad last week. (NASASpaceflight – bocachicagal)

Confirmed by Elon Musk, this included significantly increasing the length of Raptor SN03’s latest static fires, culminating in an April 27th test that lasted ~40 seconds. Above all else, long test fires are necessary to demonstrate that Raptor can reliably operate for dozens of seconds at a time, given that any failure leading to a loss of thrust could cause Starhopper – basically a controlled explosive device – to fall out of the sky. The famous Musk/SpaceX ethos of moving fast and breaking things does not preclude a pragmatic attitude towards the destruction of facilities and prototypes that could take months and millions of dollars to rebuild.

The ETA of future hop tests is unclear. For the time being, it appears that SpaceX’s South Texas facilities will be caught up in construction work for at least another week. Whether or not Raptor SN03 is next in line for installation on Starhopper, SpaceX will likely put it through several more long-duration static fires before moving ahead with untethered hop tests. All things considered, the rough Starship prototype is unlikely to restart powered testing for another two or so weeks. Stay tuned!

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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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Tesla addresses door handle complaints with simple engineering fix

“We’ll have a really good solution for that. I’m not worried about it.”

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Tesla Model S self-presenting door handle
Tesla Model S self-presenting door handle (Credit: TesBros)

Tesla is going to adjust one heavily scrutinized part of its vehicles after recent government agencies have launched probes into an issue stemming from complaints from owners.

Over the past few days, we have reported on the issues with Tesla’s door handle systems from both the Chinese and American governments.

In China, it dealt with the Model S, while the United States’ National Highway Traffic Safety Administration (NHTSA) reported nine complaints from owners experiencing issues with 2021 Model Ys, as some said they had trouble entering their car after the 12V battery was low on power.

Bloomberg, in an interview with Tesla Chief Designer Franz von Holzhausen, asked whether the company planned to adjust the door handle design to alleviate any concerns that regulatory agencies might have.

Regarding the interior latch concerns in the United States:

  • Von Holzhausen said that, while a mechanical door release resolves this problem, Tesla plans to “combine the two” to help reduce stress in what he called “panic situations.”
  • He also added that “it’s in the cars now…The idea of combining the electronic and the manual one together in one button, I think, makes a lot of sense.” Franz said the muscle memory of reaching for the same button will be advantageous for children and anyone who is in an emergency.

Regarding the exterior door handle concerns in China:

  • Von Holzhausen said Tesla is reviewing the details of the regulation and confirmed, “We’ll have a really good solution for that. I’m not worried about it.”

The new Model Y already has emergency mechanical door release latches in the back, but combining them in future vehicles seems to be an ideal solution for other vehicles in Tesla’s lineup.

It will likely help Tesla avoid complaints from owners about not having an out in the event of a power outage or accident. It is a small engineering change that could be extremely valuable for future instances.

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Elon Musk calls out viral claim of 10,000 Tesla Optimus deal: “Fake”

For now at least, Tesla seems determined to focus on the development of Optimus V3.

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Credit: Tesla Optimus/X

Elon Musk has provided some clarification to recent reports suggesting that PharmAGRI, a US pharmaceutical and agricultural infrastructure company, is looking to deploy 10,000 Optimus robots for its operations.

Musk posted his clarification on social media platform X.

Alleged Optimus purchase

Recently, reports emerged stating that PharmAGRI Capital Partners will be tapping into Tesla’s humanoid robots for its operations. The firm claimed that it had executed a Letter of Intent with Tesla to deploy up to 10,000 Optimus Gen 3+ humanoid robots across its SuperPharm and CEA facilities. This should allow the company to automate its labor and ensure diversion control.

A comment from Lynn Stockwell, Chairwoman & CEO, suggested that the company really was partnering with Tesla. “With Tesla robotics powering our facilities and DEA-licensed infrastructure in place, we can scale with precision, meet federal sourcing mandates, and deliver therapies that are compliant, secure, and American-made,” she said. 

Elon Musk clariies

News of PharmAGRI’s Optimus claims quickly spread on social media, though some Tesla watchers argued that it seemed unlikely that the EV maker will commit two legions of Optimus robots to a rather unknown company this early. Some pointed out that Tesla typically commits to high-profile customers to test its early products, such as PepsiCo with the Tesla Semi. 

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Photos from PharmAGRI’s website depicting Tesla Optimus bots, as well as the rather basic look of the website itself, also brought more reservations to the company’s claims. Ultimately, Elon Musk weighed in on the matter, responding to a post about PharmAGRI’s Optimus-filled webpage. Musk was quick and direct, simply stating, “Fake.”

Elon Musk’s comments were quite unsurprising considering that Optimus is still very much in active development, and thus, it is quite unlikely that the company is already taking orders or even Letters of Intent from potential customers at this time. For now at least, Tesla seems determined to focus on the development of Optimus V3, which Musk has noted will be “sublime.”

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Elon Musk: Self-sustaining city on Mars is plausible in 25-30 years

Musk noted that true self-sufficiency requires Mars to develop “all the ingredients of civilization.”

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Credit: Elon Musk/X

Elon Musk has stated that a self-sustaining human settlement on Mars could be established in 25-30 years, provided launch capacity increases dramatically in the coming decades. 

Speaking at the All-In Summit, the SpaceX CEO said building a self-sufficient colony depends on exponential growth in “tonnage to Mars” with each launch window, highlighting Starship’s role as the company’s pathway to interplanetary initiatives.

Mars settlement goals

Musk noted that true self-sufficiency requires Mars to develop “all the ingredients of civilization,” from food production to microchip manufacturing. Starship Version 3 is expected to support the first uncrewed Mars test flights, while future iterations could reach 466 feet in height and deliver larger payloads critical for settlement. Ultimately, Musk stated that an aggressive timeline for a city on Mars could be as short as 30 years, as noted in a Space.com report.

“I think it can be done in 30 years, provided there’s an exponential increase in the tonnage to Mars with each successive Mars transfer window, which is every two years. Every two years, the planets align and you can transfer to Mars. 

“I think in roughly 15, but maybe as few as 10, but 10-15-ish Mars transfer windows. If you’re seeing exponential increases in the tonnage to Mars with each Mars transfer window, then it should be possible to make Mars self-sustaining in about call it roughly 25 years,” Musk said. 

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Starship’s role

Starship has flown in a fully stacked configuration ten times, most recently in August when it completed its first payload deployment in orbit. The next flight will close out the Version 2 program before transitioning to Starship Version 3, featuring Raptor 3 engines and a redesigned structure capable of lifting over 100 tons to orbit.

While SpaceX has demonstrated Super Heavy booster reuse, Ship reusability remains in development. Musk noted that the heat shield is still the biggest technical hurdle, as no orbital vehicle has yet achieved rapid, full reuse.

“For full reusability of the Ship, there’s still a lot of work that remains on the heat shield. No one’s ever made a fully reusable orbital heat shield. The shuttle heat shield had to go through nine months of repair after every flight,” he said. 

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