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SpaceX’s Starship engine breaks Russian rocketry record held for two decades

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SpaceX CEO Elon Musk says the company’s Raptor engine, meant to power Starship and Super Heavy, has surpassed a rocketry record held by Russian scientists and engineers for more than two decades.

Known as combustion chamber pressure, Raptor has reportedly surpassed a modern Russian engine known as the RD-180, reaching forces equivalent to one Tesla Model 3 balanced on every square inch of Raptor’s combustion chamber, the hardware directly adjacent to a rocket engine’s bell-shaped nozzle.

First and foremost, it’s far too early to actually crown Raptor as the new official record-holder for combustion chamber pressure. RD-180 has been reliably flying on ULA’s Atlas V rocket with chamber pressures as high ~257.5 bar (3735 psi) since the year 2000, while Raptor has been performing subscale integrated testing for roughly two years and full-scale integrated testing for less than seven days. As such, the fact that full-scale Raptor has achieved ~269 bar (3900 psi) is an almost unbelievably impressive achievement but probably shouldn’t be used to jump to any conclusions just yet.

Thanks to the 10-20% performance boost supercool liquid methane and oxygen will bring Raptor, currently stuck using propellant just barely cold enough to remain liquid, the engine performing tests could already be made to reach its design specification of 300+ bar (4350+ psi), although Musk cautioned that he wasn’t sure Raptor would be able to survive that power in its current iteration. Nevertheless, 250 bar is apparently more than enough to operate Starship and its Super Heavy booster during most regimes of flight, although maximum thrust (and thus max chamber pressures) is probably desirable for the first minute or so after launch when gravity losses are most significant.

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Ultimately, the sheer speed of SpaceX’s full-scale Raptor test program is easily the most impressive and encouraging aspect of the brand new engine design. While SpaceX does tend towards testing to destruction over putting on kid-gloves around flight or development hardware, it’s safe to say that even SpaceX would avoid frivolously destroying the first full-scale Raptor after just a few dozen seconds of integrated hot-fire testing, indicating that no major red flags have cropped up since the company’s propulsion team began testing on February 3rd. In fact, Musk estimated that six separate static-fires have been performed with Raptor in the seven days since its first ignition.

As of 2017, Raptor’s McGregor, Texas test cell was fundamentally capped at test durations under 100 seconds, making comparisons difficult. Still, the best possible recent point of comparison to Raptor’s test program can be found in NASA’s series of tests of Space Shuttle engines in preparation for the Space Launch System (SLS) rocket, an expendable launch vehicle being built by Boeing, Aerojet-Rocketdyne, NGIS (formerly Orbital-ATK), and others with NASA funds. Known as RS-25 under the SLS Program, the Space Shuttle engines being test-fired by NASA have already performed multiple full-duration missions to orbit and back on the four Space Shuttle orbiters built. After half a decade in storage, they are being re-tested (effectively acceptance testing) to ensure that they are ready to be expended on SLS launches.

In the first round of 2015 tests, NASA’s Stennis Space Center test stage supported six RS-25 static-fires total, ranging from two weeks to almost five months between tests. RS-25 testing has remained on a similar schedule in 2016-2018, averaging 4-6 tests annually with no fewer than two weeks between static-fires. Given that the vast majority of those ex-Space Shuttle Main Engine tests tend to last hundreds of seconds, it’s not a perfect comparison, but it offers at least a general idea of just how incredible it is to see a groundbreaking engine like Raptor test-fired almost daily just days after it was installed on a test stand for the first time.

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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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NASA taps SpaceX for more astronaut missions as Boeing Starliner remains grounded

NASA just gave SpaceX a $946 million contract for three more astronaut missions through 2030.

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NASA has awarded SpaceX a $946 million contract modification covering three more astronaut missions to the International Space Station, according to an announcement the agency published Friday. The award adds Crew-15, Crew-16, and Crew-17 to SpaceX’s existing Commercial Crew Transportation Capability contract, bringing the agreement’s total value to $5.92 billion across 17 flights.

SpaceX confirmed the award on X, writing that it was excited for Falcon 9 and Dragon to launch NASA’s Crew-15, 16, and 17 missions to the Space Station from Florida. The new missions cover ground, launch, in orbit, and return operations, along with cargo transport and a lifeboat capability while docked at the station, and the period of performance runs through 2030.

The award follows a notice of intent NASA issued in May, when the agency first signaled it would purchase up to six additional post certification missions from SpaceX. Teslarati covered that filing at the time, noting NASA cited technical issues and schedule delays encountered by Boeing as a driving factor. Friday’s contract modification locks in three of those six missions, with the remaining three left open for NASA to award later, potentially to Boeing if Starliner clears certification.

Boeing’s CST-100 Starliner has still not flown an operational crew rotation mission for NASA. The spacecraft’s most recent crewed test flight in 2024 ended without the astronauts returning aboard Starliner, and the company has spent the time since working through thruster problems. SpaceX President Gwynne Shotwell said this week that SpaceX is not retiring Crew Dragon today, for sure, while stopping short of committing to fly it past 2030.

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Crew-12 is currently docked at the space station, and NASA has said Crew-13 is targeting a launch in the coming weeks. The newly awarded Crew-15 through Crew-17 missions extend SpaceX’s role as NASA’s primary way of getting astronauts to and from orbit well into the back half of the decade, regardless of what happens with Starliner or Starship in the meantime.

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Investor's Corner

New drone video shows Tesla’s Optimus Factory reaching a turning point

New drone footage shows Tesla’s dedicated Optimus factory steel frame nearing completion at Giga Texas.

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Tesla’s dedicated Optimus factory at Gigafactory Texas is closing in on a finished steel frame, according to drone footage posted Thursday afternoon by longtime site observer Joe Tegtmeyer. In the video, Tegtmeyer said structural steel assembly is now about five column grids away from reaching the building’s north perimeter beam, putting the primary skeleton in its final stretch roughly six months after Tesla broke ground on the North Campus site in late March.

Tegtmeyer’s footage shows concrete already going in on three upper floors while crews continue laying rebar and pouring grade beam footings at ground level. That kind of parallel work, steel rising at one end of the site while concrete sets at the other, is a scheduling approach Tesla used at the original Giga Texas building and appears to be repeating here to save time before the plant’s targeted 2027 production start.

Teslarati has tracked the building’s progress since Tesla confirmed construction was officially underway in May, when the first steel structure went up on what was then bare, reclaimed land. The facility is part of a more than 5.2 million square foot expansion of Giga Texas’s North Campus that Tesla has said will eventually run nearly the length of the existing vehicle factory, over 4,000 feet, while sitting somewhat narrower. Musk has pegged the long term output target at 10 million Optimus units a year once the line is running at full capacity, a volume that would dwarf the one million unit pilot line Tesla is standing up separately at its Fremont, California factory.

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Tesla Giga Texas to feature massive Optimus V4 production line

The Texas facility sits alongside another major buildout on the same campus. Terafab, the joint Tesla and SpaceX chip fabrication plant that will eventually supply the silicon running Optimus units in the field. Housing robot assembly and chip production on the same grounds is a deliberate supply chain decision, cutting down on the shipping and lead time that would otherwise sit between the two.

Tesla has not given an updated timeline beyond its previously stated goal of bringing high volume Optimus production online at the site in the summer of 2027. Fremont’s smaller pilot line began mass producing the current Gen 3 robot in January, with that plant expected to build tens of thousands of units this year primarily to generate the real world data Tesla needs to refine the robot’s software before Giga Texas ramps up. Six months of visible construction progress, tracked almost entirely through Tegtmeyer’s recurring drone flights, gives the clearest outside look yet at how seriously Tesla is treating that 2027 deadline.

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Investor's Corner

Tesla and SpaceX take “Terafab” Trademark fight to Federal Court

Tesla and SpaceX sue a small Illinois firm after cease and desist letters over Terafab.

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SpaceX Terafab rendering

Tesla and SpaceX are asking a federal judge to rule that their planned Terafab chip factory does not infringe a small Illinois company’s trademark, a request that arrives only after months of quiet negotiation broke down this summer.

The dispute traces to May 18, when Tesla filed three U.S. trademark applications for “Terafab” and “Tesla Terafab,” covering semiconductor chips and related chip making services. TERA-print LLC, a nanotechnology company that has held a federal trademark for “Tera-Fab” since 2021, responded five days later with a cease and desist letter. According to the lawsuit, first reported by Reuters, TERA-print argued that Tesla and SpaceX’s use of “Terafab” would confuse consumers familiar with its own trademark, which covers a desktop photolithography printer sold to researchers for sensor and bioengineering work.

What stands out in the filing is the timing of TERA-print’s own paperwork. One day before sending that cease and desist letter, on May 22, TERA-print applied to expand its existing registration to cover semiconductor materials, silicon chips, nanoelectronic devices and AI design services, categories it had not previously claimed. Tesla and SpaceX call that filing opportunistic in their complaint, noting it arrived two months after Tesla’s public Terafab announcement and just days after Tesla’s own trademark applications went in.

Elon Musk launches TERAFAB: The $25B Tesla-SpaceXAI chip factory that will rewire the AI industry

By June 10, TERA-print was threatening to sue for federal trademark infringement, false designation of origin and unfair competition, the complaint states. Rather than wait to be sued, Tesla, SpaceX and SpaceXAI met with TERA-print six separate times between June and August trying to resolve the dispute directly. Those talks collapsed, and the companies filed for declaratory judgment this week in the U.S. District Court for the Western District of Texas, asking a judge to find that “Terafab” does not infringe TERA-print’s mark before TERA-print can file a claim of its own.

TERA-print isn’t backing down. The company told PCMag it discussed a settlement with Tesla as recently as September 2 and feels misled by what it called Tesla’s professed interest in settling. Its CTO, Andrey Ivankin, said TERA-print holds a Defense Department contract to fabricate semiconductors and partially owns Mattiq Inc., an AI company built on TERA-print’s products, and that the company will vigorously defend its rights.

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Tesla and SpaceX argue the overlap is superficial. Terafab is planned as a $16.8 billion complex spanning roughly 100 million square feet at the Grimes County site SpaceX confirmed last month, built to produce chips for Optimus robots, Tesla’s AI computing needs and SpaceX’s orbital data center ambitions, a scale and purpose the companies say no reasonable consumer would confuse with a tabletop lab printer. TERA-print’s product line has stayed focused on lithography tools for biological and sensor research since it registered its mark in 2021.

The trademark fight is the second legal dispute tied to the Terafab project in the past week, following a separate SpaceX suit aimed at keeping company records about the facility out of public view, as KBTX reported. Whether construction proceeds under the Terafab name now depends on a federal judge in Austin.

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