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SpaceX’s Starlink satellites may use unique solar array deployment mechanism

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Spotted on an official SpaceX T-shirt commemorating Starlink’s first two prototype satellites and corroborated through analysis of limited public photos of the spacecraft, SpaceX appears to be testing a relatively unique style of solar arrays on the first two satellites launched into orbit, known as Tintin A (Alice) and B (Bob).

It’s difficult to judge anything concrete from the nature of what may be immature prototypes, but SpaceX’s decision to take a major step away from its own style of solar expertise – Cargo Dragon’s traditional rigid panel arrays – is almost certainly motivated by a need to push beyond the current state of the art of satellite design and production.

Unlike any discernible solar panel deployment mechanism with a flight history, SpaceX’s Starlink engineers seem to have taken a style of deployment used successfully on the International Space Station and mixed it with a modern style of solar arrays, relying on several flexible panels that can be efficiently packed together and designed to be extremely lightweight. While a major departure from SpaceX’s successful Cargo Dragon solar arrays, the mechanisms visible on the Tintins seem to have the potential to improve upon the packing efficiency, ease of manufacturing, and number of failure modes present on Dragon’s panels.

In essence, those three motivations are indicative of the challenges SpaceX’s Starlink program must solve in a more general sense. In order to even approach SpaceX’s operational aspirations for Starlink (i.e. high-speed internet delivered from space almost anywhere on Earth), the company will need to find ways to mass-produce hundreds or thousands of high-performance satellites annually at a price-per-unit unprecedented in the history of commercial satellites, all while keeping the weight and volume of each satellite as low as possible (no more than a few hundred kilograms).

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To give an idea of where the industry currently stands, satellite internet provider Viasat launched its own Viasat-2 spacecraft in 2017. Weighing in around 6500 kg (14300 lb), the immense satellite cost at least $600 million and offers an instantaneous bandwidth of 300 gigabits per second, impressive but also gobsmackingly expensive at $2 million/Gbps. To ever hope to make Starlink a reality, SpaceX will need to beat that value by at least a factor of 5-10, producing Starlink satellites for no more than $1-3 million apiece ($4.5B-$13.5B alone to manufacture the initial 4,425 satellite constellation) with a bandwidth of 20 Gbps – baselined in official statements.

Compared to the state of the art, a $1 million satellite with optical (laser) interlinks, multiple phased array antennae, electric ion propulsion, two 1-2 kW solar arrays, and bandwidth on the order of 20 Gbps is – to put it nicely – wildly ambitious. Fundamentally, SpaceX will need to revolutionize design and mass-production of all of the above subcomponents, and perhaps the unfamiliar solar arrays present on the Tintin twins are a first step towards tackling at least one of those revolutions-in-waiting.

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According to CEO Elon Musk, another set of prototype satellites will likely be launched and tested in orbit before settling on a finalized Starlink design.


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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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U.S. Judge dismisses lawsuit against SpaceX Starship Boca Chica launch site

The ruling found that the FAA had met its obligations in reviewing the potential environmental effects of Starship launches.

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(Credit: SpaceX)

A U.S. district court judge has dismissed a lawsuit brought by conservation groups challenging the Federal Aviation Administration’s approval of SpaceX’s expanded rocket launch operations in Boca Chica, Texas. 

The ruling, issued Monday, found that the FAA had met its obligations in reviewing the potential environmental effects of Starship launches.

FAA review withstands legal challenge

The lawsuit centered on whether the FAA properly assessed the impact of SpaceX’s operations on endangered wildlife, including ocelots, jaguarundis, and Kemp’s Ridley sea turtles, as noted in a report from The Guardian. The plaintiffs argued that noise, light pollution, and construction activity degraded the surrounding habitat, which also serves as nesting grounds for threatened shorebirds.

The lawsuit cited SpaceX’s April 2023 Starship test, which destroyed its launchpad and scattered debris across a large area. The blast reportedly ignited a grassfire and damaged wildlife habitats, including a bobwhite quail nest.

Judge Carl Nichols, for his part, ruled that the FAA had satisfied its obligation“to take a hard look at the effects of light on nearby wildlife.” The decision effectively cleared a regulatory hurdle for SpaceX, which has been working to expand Starship launch activity at its Boca Chica facility.

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A continued ramp

SpaceX continues to scale its operations nationwide. Beyond Starship, the company is also seeking approval to nearly double Falcon rocket launches from Vandenberg Space Force Base in California, from 50 annually to 95. 

Former President Trump has also shared his intention to increase U.S. launch capacity, setting a target for substantial growth by 2030. Considering that SpaceX is by far the world’s dominant launch provider, Trump’s support for more launches will likely benefit the private space company.

For now, at least, the ruling should allow continued expansion at a time when Starship remains central to long-term goals such as Mars missions and NASA’s Artemis program.

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SpaceX to expand Central Texas facility with $8M Bastrop project

Bastrop is already the site of several Elon Musk-led ventures.

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Credit: SpaceX

SpaceX is set to expand its presence in Central Texas with an $8 million project to enlarge its Bastrop facility, as per state filings. 

The 80,000-square-foot addition, which is scheduled to begin construction on September 24 and wrap in early January 2026, was registered with the Texas Department of Licensing and Regulation and initially reported by My San Antonio

New investment

Bastrop is already the site of several Elon Musk-led ventures. The upcoming expansion will extend SpaceX’s office at 858 FM 1209, near Starlink’s operations and The Boring Company’s facilities. Just down the road, X is housed in the Hyperloop Plaza at 865 FM 1209.

SpaceX’s expansion reflects a steady buildup of resources in Bastrop since the private space firm established its presence in the area. The addition was praised by Tesla Governor Greg Abbott, who wrote on X that the expansion will “bring more jobs, innovations and will strengthen Starlink’s impact worldwide.” 

State support

In March, Gov. Greg Abbott announced a $17.3 million state grant to SpaceX for an “expansion of their semiconductor research and development (R&D) and advanced packaging facility in Bastrop.” The project is expected to create more than 400 new jobs and generate over $280 million in capital investment.

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Following the grant award, the Texas Governor also noted that SpaceX’s facility would be growing by 1 million square feet across three years to boost its Starlink program. SpaceX’s Starlink division is among the company’s fastest-growing segments, with the satellite internet system connecting over 6 million users and counting worldwide. 

Recent reports have also indicated that Starlink has struck a deal with EchoStar to acquire 50 MHz of exclusive S-band spectrum in the United States and global Mobile Satellite Service (MSS) licenses. This should pave the way for Starlink to provide 5G coverage worldwide, even in remote areas. 

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Starlink’s EchoStar spectrum deal could bring 5G coverage anywhere

The agreement strengthens Starlink’s ability to expand its mobile coverage worldwide.

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Credit: SpaceX/X

SpaceX has struck a deal with EchoStar to acquire 50 MHz of exclusive S-band spectrum in the United States and global Mobile Satellite Service (MSS) licenses, paving the way for its next-generation Starlink Direct to Cell constellation. 

The agreement strengthens Starlink’s ability to expand its mobile coverage worldwide. With the upgraded system, SpaceX aims to deliver full 5G connectivity to unmodified cell phones and eliminate mobile dead zones worldwide.

Expanding mobile coverage

Starlink’s Direct to Cell service was first launched in early 2024 with satellites designed to connect directly to standard LTE mobile devices. Within days of deployment, engineers demonstrated texting from unmodified phones, followed by video calling. Over the past 18 months, SpaceX has grown the system to more than 600 satellites, which now offer service across five continents. Today, Starlink Direct to Cell is considered the largest 4G coverage provider worldwide, connecting over 6 million users and counting, according to SpaceX in a post.

The constellation integrates with Starlink’s broader fleet of 8,000 satellites via a laser mesh network. Operating at 360 kilometers (224 miles) above Earth, the satellites connect directly to devices without hardware or firmware modifications. The system is already supporting messaging, video calls, navigation, social media apps, and IoT connectivity in remote areas.

Next-generation system

Through its new EchoStar spectrum acquisition, SpaceX plans to develop a second-generation constellation with far greater capacity. The upgraded satellites will leverage SpaceX-designed silicon and advanced phased array antennas to increase throughput by 20x per satellite and increase total system capacity by more than 100x. These enhancements are expected to support full 5G cellular connectivity in remote areas, with performance comparable to terrestrial LTE networks.

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Partnerships with major mobile carriers remain central to Starlink’s expansion. Operators including T-Mobile in the United States, Rogers in Canada, KDDI in Japan, and Kyivstar in Ukraine are integrating Direct to Cell services for coverage in rural areas and during emergencies. The service has already provided critical communication during hurricanes, floods, and wildfires, enabling millions of SMS messages and emergency alerts to be delivered when ground networks were unavailable.

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