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SpaceX Starship prototype charred but intact after catching fire [photos]

SpaceX employees inspect Starship SN4 for the first time some two days after the rocket finished its third Raptor engine test. (NASASpaceflight - bocachicagal)

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SpaceX teams have finally safed the fourth full-scale Starship prototype nearly two days after a Raptor engine test caught it on fire, an anomaly that left the massive rocket charred and damaged – but still intact.

While SN4’s survival is a welcome and unexpected outcome, the fire that broke out near the base of the rocket caused damage that will have to be repaired, while the fault that allowed that fire to occur in the first place will also need to be rectified. Had the same events transpired during the ship’s inaugural flight test, things could have gone even further south after the rocket lifted off, carrying it away from remotely-controlled water jets used to suppress unplanned fires on the pad.

Thankfully, SpaceX’s focus on testing, testing, and testing some more meant that Starship SN4’s minor self-immolation occurred on the ground when the stakes – while high – were much lower than they would have been with an airborne rocket. The problems uncovered will, of course, need to be fixed, inevitably delaying the ship’s first flight test, but odds are that SN4 now has a better shot at success thanks to those hiccups.

Starship SN4 has thankfully survived a ~48-hour ordeal that may have left the rocket partially uncontrolled. (NASASpaceflight – bocachicagal)

Thanks to the fact that Starships are constructed almost entirely out of steel, a little (or a lot of) fire shouldn’t theoretically be much of a problem. However, SpaceX has taken a rather freeform approach to its early Starship SNx prototypes, opting to bolt, weld, or tape on the vast majority of external hardware with little or no protection from the elements, including fires ignited by the ships themselves.

With SN4, it appears that the pressure jump experiences immediately after Raptor ignition (the ship’s third such test) shook some methane-related plumbing loose. Raptor continued to burn for another five or so seconds after that minor failure, shutting down as planned – but not before it ignited the methane the burst pipe was leaking. Additionally, after that new plume of boiling liquid methane caught fire, the fire it sustained proceeded to ignite insulation wrapped around the rocket’s launch. It burned vigorously, likely helping to damage wiring, ultimately causing SpaceX to partially lose control of the rocket and preventing attempts to inspect and fix the damage for two full days.

A May 8th view of the pipe (bottom right of Starship SN4) that failed on May 19th, starting a fire and damaging the rocket. (NASASpaceflight – bocachicagal)
A large scorch mark and blackened cabling are the only signs on Starship that anything went wrong on May 19th. (NASASpaceflight – bocachicagal)
Around the other side of the rocket, (apparently flammable) insulation haphazardly wrapped around part of the launch mount ~24 hours before testing caught fire and burned aggressively. The leftovers are pictured here on May 21st. (NASASpaceflight – bocachicagal)

It’s safe to say that SpaceX is probably going to prioritize avoiding the series of events that caused May 19th’s anomaly from here on out, considering that things could have easily gone much worse. Thankfully, whatever control SpaceX or the rocket itself retained after wire damage allowed it to safely offload its flammable propellant and vent expanding gases to prevent SN4’s tanks from bursting. Installing highly flammable insulation approximately 10 feet away from an active Raptor engine and giant controlled fire and explosion was also inadvisable and probably won’t be repeated.

(NASASpaceflight – bocachicagal)

Thankfully, the damage is clearly minimal and Starship SN4 survived the ordeal otherwise unscathed. With any luck, inspections and repairs will be quick and easy and SpaceX – as NASASpaceflight reporter Michael Baylor notes – will be able to complete an identical static fire test without starting a fire on Starship SN4. SpaceX has requested a new road closure (signifying planned testing) on May 28th with backup windows on May 29th and June 1st.

Thanks to Starship SN4’s unplanned delays, it now looks quite likely that SpaceX’s next full-scale Starship prototype (SN5) will be completed – or nearly so – by the time that its predecessor is cleared for flight. “Too many Starships” is certainly a welcome problem to have.

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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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Starlink achieves major milestones in 2025 progress report

Starlink wrapped up 2025 with impressive growth, adding more than 4.6 million new active customers and expanding service to 35 additional countries, territories, and markets.

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Credit: Starlink/X

Starlink wrapped up 2025 with impressive growth, adding more than 4.6 million new active customers and expanding service to 35 additional countries, territories, and markets. The company also completed deployment of its first-generation Direct to Cell constellation, launching over 650 satellites in just 18 months to enable cellular connectivity.

SpaceX highlighted Starlink’s impressive 2025 progress in an extensive report.

Key achievements from Starlink’s 2025 Progress

Starlink connected over 4.6 million new customers with high-speed internet while bringing service to 35 more regions worldwide in 2025. Starlink is now connecting 9.2 million people worldwide. The service achieved this just weeks after hitting its 8 million customer milestone.

Starlink is now available in 155 markets, including areas that are unreachable by traditional ISPs. As per SpaceX, Starlink has also provided over 21 million airline passengers and 20 million cruise passengers with reliable high-speed internet connectivity during their travels.

Starlink Direct to Cell

Starlink’s Direct to Cell constellation, more than 650 satellites strong, has already connected over 12 million people at least once, marking a breakthrough in global mobile coverage.
Starlink Direct to Cell is currently rolled out to 22 countries and 6 continents, with over 6 million monthly customers. Starlink Direct to Cell also has 27 MNO partners to date.

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This year, SpaceX completed deployment of the first generation of the Starlink Direct to Cell constellation, with more than 650 satellites launched to low-Earth orbit in just 18 months. Starlink Direct to Cell has connected more than 12 million people, and counting, at least once, providing life-saving connectivity when people need it most,” SpaceX wrote.

starlinkProgressReport_2025 by Simon Alvarez

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Giga Nevada celebrates production of 6 millionth drive unit

To celebrate the milestone, the Giga Nevada team gathered for a celebratory group photo. 

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Tesla’s Giga Nevada has reached an impressive milestone, producing its 6 millionth drive unit as 2925 came to a close.

To celebrate the milestone, the Giga Nevada team gathered for a celebratory group photo. 

6 million drive units

The achievement was shared by the official Tesla Manufacturing account on social media platform X. “Congratulations to the Giga Nevada team for producing their 6 millionth Drive Unit!” Tesla wrote. 

The photo showed numerous factory workers assembled on the production floor, proudly holding golden balloons that spelled out “6000000″ in front of drive unit assembly stations. Elon Musk gave credit to the Giga Nevada team, writing, “Congrats on 6M drive units!” in a post on X.

Giga Nevada’s essential role

Giga Nevada produces drive units, battery packs, and energy products. The facility has been a cornerstone of Tesla’s scaling since opening, and it was the crucial facility that ultimately enabled Tesla to ramp the Model 3 and Model Y. Even today, it serves as Tesla’s core hub for battery and drivetrain components for vehicles that are produced in the United States.

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Giga Nevada is expected to support Tesla’s ambitious 2026 targets, including the launch of vehicles like the Tesla Semi and the Cybercab. Tesla will have a very busy 2026, and based on Giga Nevada’s activities so far, it appears that the facility will be equally busy as well.

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Tesla Supercharger network delivers record 6.7 TWh in 2025

The network now exceeds 75,000 stalls globally, and it supports even non-Tesla vehicles across several key markets.

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tesla-diner-supercharger
Credit: Tesla

Tesla’s Supercharger Network had its biggest year ever in 2025, delivering a record 6.7 TWh of electricity to vehicles worldwide. 

To celebrate its busy year, the official @TeslaCharging account shared an infographic showing the Supercharger Network’s growth from near-zero in 2012 to this year’s impressive milestone.

Record 6.7 TWh delivered in 2025

The bar chart shows steady Supercharger energy delivery increases since 2012. Based on the graphic, the Supercharger Network started small in the mid-2010s and accelerated sharply after 2019, when the Model 3 was going mainstream. 

Each year from 2020 onward showed significantly more energy delivery, with 2025’s four quarters combining for the highest total yet at 6.7 TWh.

This energy powered millions of charging sessions across Tesla’s growing fleet of vehicles worldwide. The network now exceeds 75,000 stalls globally, and it supports even non-Tesla vehicles across several key markets. This makes the Supercharger Network loved not just by Tesla owners but EV drivers as a whole.

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Resilience after Supercharger team changes

2025’s record energy delivery comes despite earlier 2024 layoffs on the Supercharger team, which sparked concerns about the system’s expansion pace. Max de Zegher, Tesla Director of Charging North America, also highlighted that “Outside China, Superchargers delivered more energy than all other fast chargers combined.”

Longtime Tesla owner and FSD tester Whole Mars Catalog noted the achievement as proof of continued momentum post-layoffs. At the time of the Supercharger team’s layoffs in 2024, numerous critics were claiming that Elon Musk was halting the network’s expansion altogether, and that the team only remained because the adults in the room convinced the juvenile CEO to relent.

Such a scenario, at least based on the graphic posted by the Tesla Charging team on X, seems highly implausible. 

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