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SpaceX sends Starship heat shield “bakery” to Boca Chica

(NASASpaceflight - bocachicagal)

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At the same time as SpaceX is assembling hardware and manufacturing dozens of Raptor engines for Starship’s inaugural orbital test flight, it’s also preparing for what will follow.

Last week, a local photographer captured photos of one of the many dozens of deliveries that arrive at SpaceX’s Boca Chica Starship factory every month – notable this time around because of package labels that reference a “heat shield” and “mini bakery.” In any other case, it would’ve been just another nondescript delivery – likely carrying the latest batch of the ceramic Starship heat shield tiles SpaceX currently manufactures in Cocoa Beach and Cape Canaveral, Florida.

However, as the photographer (@StarshipGazer) that captured the images noted, that Florida Starship heat shield factory just so happens to be colloquially known as “The Bakery” by the SpaceX team that runs it.

As the nickname would suggest, The Bakery is one of two main Florida-based facilities tasked with turning raw materials into the black, hexagonal heat shield tiles that have begun to spread across the exterior of Starship prototypes. The June 7th delivery of a “mini bakery” strongly implies that SpaceX has now begun to build out some limited capacity for heat shield tile production at Boca Chica itself – under the main Starship factory roof, in other words.

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While the number of tiles present has only really begun to grow in the last six or so months, SpaceX has been building, testing, and refining Starship’s heat shield technology for more than two years. SpaceX’s custom-built ceramic tiles made their first public appearances in July and August 2019, first launching into orbit on a Cargo Dragon spacecraft and later tagging along on Starhopper’s spectacular 150m (~500 ft) hop a few weeks later. Dragon went on to reenter and splash down in the Pacific Ocean without issue about a month later, effectively marking the first successful orbital reentry of (part of) a Starship heat shield.

With Starship SN8 heralding the arrival of full-size prototype flight tests in the last few months of 2020, SpaceX began to substantially increase the number of tiles installed on Starships, jumping from a handful to hundreds within a few months. Although Starship SN15’s successful May 5th, 2021 launch and landing likely means it will never fly, Starship SN16 was outfitted with more than a thousand tiles (and SN15 flew with almost as many). While those tiles have essentially zero experience acting as a heat shield on Starship prototypes, launching them on suborbital test flights still subjects those heat shield installations to major thermal and mechanical stresses similar to (or worse than) what Starship will need to withstand during launch and after reentry.

Given that at least a few of the ceramic tiles installed on each prototype have invariably shattered at some point during testing, it’s unclear exactly how successful those coupon tests have been. Unlike the Space Shuttle, which also relied almost exclusively on catastrophically fragile ceramic heat shield tiles, Starship’s tiles are mounted directly to its hull and that hull is made out of steel instead of an aluminum frame. In theory, Starship’s structure can thus withstand – and remain functional – at temperatures approaching 800°C (1500°F), whereas the Shuttle’s heat shield had to keep the vehicle’s aluminum structure below ~180°C (360°F).

Of course, Starship has yet to even attempt to survive an orbital-velocity reentry with some 10,000 ceramic heat shield tiles mounted directly to its steel skin. If successful, SpaceX’s ultra-simple design could give Starship massive advantages over the Shuttle, which ultimately proved to be more dangerous than traditional crew capsules and about as expensive as a similarly capable expendable rocket. But Starship’s heat shield has its work cut out for it to prove that the vast spacecraft is truly up to the challenge of orbital reentry and safe, reliable reuse.

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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 skeptics will hate what this new reliability study says

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Credit: Tesla

In a notable shift for electric vehicle perceptions, Tesla has emerged as a standout performer in the latest iSeeCars longevity study, which analyzed over 174 million used vehicles.

The data reveals that Tesla models have a 4.6 percent chance of reaching 250,000 miles, matching the industry average of 4.8 percent and tying for sixth place among 32 brands. This positions Tesla ahead of many established names, including Subaru (2.3 percent, roughly half of Tesla’s rate), Nissan (2.4 percent), Mazda, BMW, Mercedes-Benz, and Porsche.

Toyota leads with an impressive 17.8 percent likelihood, followed by Lexus (12.8 percent), Honda, and Acura. Yet Tesla’s result stands out for a relatively young EV brand. Experts attribute this to the inherent simplicity of electric powertrains: fewer moving parts mean no oil changes, timing belts, or complex engine components that typically fail in internal combustion vehicles.

Fewer things to maintain means fewer things to break, and ultimately, fewer things to go wrong.

This design advantage helps Teslas defy unfounded skepticism about battery longevity and overall durability, two things that have plagued the company from outsider perspectives without much proof.

The iSeeCars reliability ratings further bolster Tesla’s case. The Tesla Model S earns a strong 7.9/10 reliability score, ranking No. 1 out of 35 most reliable electric cars. It boasts a predicted average lifespan of about 154,419 miles (around 16.9 years) and a 21.9 percent chance of hitting 200,000 miles.

Tesla, as an electric car brand, also scores 7.9/10 overall, securing the top spot among electric vehicle manufacturers in several luxury and segment categories.

Real-world examples reinforce the data. High-mileage Teslas, including Model S vehicles exceeding one million miles, demonstrate that EVs can endure when properly maintained. Owners report minimal mechanical issues beyond typical wear items like tires and brakes, which regenerative braking often extends.

Tesla Model 3 hits quarter million miles with original battery and motor

This performance challenges narratives around EV reliability, especially amid mixed reports from other sources like Consumer Reports or regional inspections. iSeeCars‘ massive dataset emphasizes long-term durability over short-term defect rates, painting Tesla as a leader in sustainable, high-mileage ownership.

For buyers prioritizing longevity and low maintenance, Tesla’s results signal strong value. While no brand is flawless, factors like driving habits, climate, and software updates matter—the numbers suggest Tesla belongs among the elite for those seeking vehicles built to last.

As EV adoption grows, this iSeeCars data underscores Tesla’s engineering edge in creating enduring, future-proof automobiles.

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Tesla owner fixes common feature complaint with crafty DIY retrofit

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Credit: @mikegapinski

Tesla owners have long griped about the wireless phone charger in the Model Y and other vehicles. It often turns smartphones into miniature ovens rather than reliably topping them up.

Software engineer and Model Y owner Michał Gapiński tackled this issue head-on with a clever DIY upgrade, swapping the cooled wireless charger pad from the China-made Model YL in for the one that came standard in his vehicle.

There are several key differences between the U.S.-built Model Y’s wireless charging pad and the one that Tesla has been installing in the Model YL. The one installed in U.S.-built vehicles lacks active cooling and relies on basic heat dissipation, leading to rapid temperature buildup during charging. In contrast, the Model YL integrates a small fan for active cooling.

This design maintains lower temperatures even in warm ambient conditions, though it does not support faster Qi2 charging on iPhones. The connector matches exactly, making physical swaps feasible on compatible consoles, but coding is required to enable full functionality.

Owners in the U.S. have complained about the wireless charging pad, with many reporting that overheating is fairly common. Within 20 or 30 minutes of placing a phone on the wireless charging pad, many have reported overheating messages on their phones, which halt charging and essentially turn the pad into a fancy place to rest your phone.

Many owners have opted to simply plug their phones into a charging cord. Tesla has acknowledged the problem by releasing several solutions for owners, including a relatively new feature that allows you to simply turn off the charging and simply act as a holder for your phone while driving.

Gapiński said that he sourced the cooled pad affordably from China, and it cost under $200 for the part.

He removed the existing console charger, swapped in the new unit, confirming a perfect connector fit, and handled the trim differences. Since the parameter isn’t fully secured, he enabled it through custom coding outside official Toolbox.

The fan activates quietly, blending with AC and seat cooling. He reported the installation was effective and the wireless charging pad worked perfectly; it even kept the phone cool as it stayed at just 86 degrees Fahrenheit. Many times, the wireless charging pad will bring the phone’s temperature well above 100 degrees, sometimes even being relatively hot to the touch.

This retrofit highlighted an elegant, owner-driven solution to a factory shortcoming. It is expected that Tesla will begin installing the cooled charging pads into new cars in the U.S. soon, and hopefully, it will offer some sort of retrofit service or kit to owners here who want to use the charging pad effectively.

For those who love to tinker, it’s an accessible upgrade, proving that innovation thrives beyond the production line.

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Tesla exec says Roadster unveil is soon — for real this time

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(Credit: teslaindiafansclub/Instagram)

The Tesla Roadster unveiling could be coming “in a few weeks,” according to the company’s Chief Designer Franz von Holzhausen, who said at the Tesla Takeover Europe Event in Austria that the all-electric hypercar could finally make its way to the production line after years of anticipation.

Von Holzhausen delivered the news just days after The Information reported that Tesla planned to push the Roadster unveiling to August. It was slated for both April and May of this year, but now it seems the company is leaning toward a late Summer event to cap off the heat with perhaps its most anticipated vehicle of all-time.

Franz has been with Tesla since 2008, and has played a pivotal role in the iconic design language the company has utilized with its vehicles. Speaking to the crowd in Austria virtually, von Holzhausen’s comments injected fresh excitement into a project that has been plagued by delays for nine years.

The second-generation Roadster promises to redefine supercar standards. Tesla’s website still highlights ambitious targets: 0-60 mph in under 1.9 seconds (with optional SpaceX thruster pack potentially achieving 1.1 seconds or less), a top speed exceeding 250 mph, and a range of about 620 miles.

Equipped with a tri-motor all-wheel-drive setup delivering over 1,000 horsepower, the four-seater aims to blend blistering acceleration, everyday usability, and innovative features like cold gas thrusters for short-hop capabilities, technology that will combine the project with SpaceX.

But years after the company promised to start production, which was slated for 2020, the timeline for the Roadster has continued to shift.

Tesla has strung along those who have put $50,000 deposits down, as well as fans and enthusiasts of the company who have been long awaiting the company to bring forth a car truly designed for the human driver, and not autonomy. The Roadster is more than just a halo vehicle for Tesla; it showcases the company’s ability to push the boundaries while incorporating synergies from other Musk companies.

However, it has to make it to production, which is something Musk and Co. have pushed back repeatedly.

As Tesla navigates Robotaxi development and broader autonomy goals, the Roadster serves as a reminder of its performance roots. If von Holzhausen’s timeline holds, fans could witness this engineering marvel by late June or early July 2026. Whether a full unveiling, demo, or initial deliveries, it marks a milestone for electric supercars.

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