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SpaceX Starship factory overflowing with new and flight-proven rockets

SpaceX has at least six separate Starship prototypes in work at its Boca Chica, Texas rocket factory. (NASASpaceflight - bocachicagal)

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After a relatively relaxed period of production and testing, SpaceX’s South Texas Starship factory is practically overflowing with new and flight-proven ships as the company prepares for the rocket’s next major tests.

Even before the one-off Starship Mk1 prototype failed a pressure test late last year, SpaceX was in the process of upgrading its Boca Chica production facilities and refining the ship’s design and manufacturing processes. Starship SN1, the first prototype built as part of that upgrade, rolled to the launch pad on February 25th, 2020, followed by Starship SN2 (turned into a test tank) just a week or so later. Starship SN3 and SN4 would both follow in early and late April, ultimately ending with the latter prototype’s spectacularly violent demise in late May.

Over the remaining three or so months, the pace of testing has slowed a bit as SpaceX’s Starship development program enters the full-scale flight testing phase. Starship SN5 began testing on July 1st, followed by SN6 around six weeks later. Both prototypes successfully hopped just 30 days apart. Now, although SpaceX still plans to hop SN5 a second time and may hop SN6 twice, too, the Starship program’s focus has shifted to high-altitude, high-velocity flight tests and the adoption of a new steel alloy.

Presumably in anticipation of a learning curve as that new steel alloy begins to be tested at full-scale for the first times, SpaceX is churning out Starship prototypes at an unprecedented pace. Intriguingly, that production ramp is hinged upon the assumption that a 304L-class steel alloy (compared to the 301 stainless steel used to build SN1 through SN6) will be as good or better than 301 steel in every significant way.

Currently, that assumption isn’t entirely baseless but is still built upon the success of Starship SN7, SpaceX’s first 304L test tank. SpaceX never confirmed its results but it’s believed that that test tank – more of a material demonstrator than an actual structural Starship prototype – surpassed all previous pressure records before it burst in June.

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Starship test tank SN7, June 15th. (NASASpaceflight – bocachicagal
SN7 is believed to have broken pressure records before it burst on June 23rd. (NASASpaceflight – bocachicagal)
A second 304L test tank – Starship SN7.1 – rolled to the test site on September 7th. (NASASpaceflight – bocachicagal)

Given that SN7 performed quite well, it’s at least a bit less surprising that SpaceX is hinging months of work and at least four full-scale Starship prototypes on an otherwise unproven steel alloy. The next big test for 304L Starships will be a second test tank known as SN7.1. Rolled to the test site on September 7th, essentially as soon as Starship SN6 was safed and returned to the factory after its hop debut, SN7.1 is significantly more complex than its sibling and will test a ~304L Raptor mount (thrust puck) and skirt section. The forces and general conditions those new parts will be subjected to are substantially different than most of what SN7 was subjected to, meaning that there is a chance that 304L steel is less optimal in different scenarios.

With any luck, SN7.1’s test campaign – scheduled to begin as early as 9pm CDT (UTC-5), September 10th (today) – will be a flawless success, proving that SpaceX’s new steel alloy is universally superior to 301 for Starship-related applications. If that’s the case, Starship SN8 – the first full new-alloy prototype – will likely be fully outfitted with a nosecone and header tanks before beginning acceptance testing.

SN8’s tank section (center) was fully stacked by late August. (NASASpaceflight – bocachicagal)
Alongside Starship tanks, SpaceX’s Boca Chica team has also been extensively prototyping upgraded Starship nose sections. Starship Mk1’s roughshod nose is visible for comparison on the far left. (NASASpaceflight – Nomadd)

Eventually, if SN7.1 aces its tests and SN8 performs well during preflight preparations, Starship SN8 could become the first prototype to launch with a full nose, header tanks, and flaps, as well as the first to fly with three Raptor engines. If Starship SN8 fails for any reason or is damaged during testing, though, it appears that SpaceX will have no shortage of ships built out of the same new steel alloy to choose from.

In just the last ten days, labeled parts and rings for Starships SN9, SN10, and SN11 have all been spotted, implying that SpaceX is concurrently building at least four new Starships. Notably, both Starships SN9 and SN11 already appear to have some of the studs needed for heat shield tile installation affixed to sections of their steel hulls. Based on the sheer number of steel ring stacks spotted over the last week, it’s also safe to assume that SN9’s tank section (and possibly SN10’s, too) is largely prefabricated.

Starship SN9’s common dome was sleeved with steel rings around August 15th. (NASASpaceflight – bocachicagal)
SN9’s aft dome and thrust puck was sleeved with steel rings around September 4th. (NASASpaceflight – bocachicagal)
Starship SN10’s thrust puck was delivered from Hawthorne, California on September 3rd. (NASASpaceflight – bocachicagal)
SN10’s forward dome was sleeved on September 8th. (NASASpaceflight – bocachicagal)
The first labeled Starship SN11 rings were spotted on September 9th. (NASASpaceflight – bocachicagal)
Two reinforced five-ring stacks will likely support nosecones on two new Starships. (NASASpaceflight – bocachicagal)

Assuming two of the in-work nosecones are ultimately meant for flight, SpaceX may already have enough hardware on hand to fully assemble two Starships (presumably SN8 and SN9) – including nosecones, header tanks, nose rings, and flaps. It’s safe to say that if SN7.1 achieves its goals, preparations for the first triple Raptor hop, 20 km (~12 mi) test flight, and skydiver-style landing attempt could come together incredibly quickly.

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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 launches its new branded Supercharger for Business with first active station

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Credit: Tesla

Tesla has officially launched its first branded Supercharger just months after initiating a new program that allows third-party companies to brand their own charging piles.

The site opened in Land O’ Lakes, Florida, and features eight V4 Supercharging stalls offering up to 325 kW of charging speed. It appears it was purchased by a company called Suncoast Credit Union. This particular branch is located Northeast of Tampa, which is on the Gulf of Mexico.

It features graphics of Florida animals, like alligators:

Tesla launched this program back in September, and it basically was a way to expand its Supercharger presence and also allow companies to pay for the infrastructure. Tesla maintains it. When it announced the “Supercharger for Business,” it said:

“Purchase and install Superchargers at your business. Superchargers are compatible with all electric vehicles, bringing EV drivers to your business by offering convenient, reliable charging.”

The program does a few things. Initially, it expands EV charging infrastructure and makes charging solutions more readily available for drivers. It can also attract people to those businesses specifically.

Tesla launches new Supercharger program that business owners will love

The chargers can also be branded with any logo that the business chooses, which makes them more personalized and also acts as an advertisement.

The best part is that the customers do not have to maintain anything about the Supercharger. Tesla still takes care of it and resolves any issues:

“We treat your site like we treat our sites. By providing you with a full-service package that includes network operations, preventative maintenance, and driver support, we’re able to guarantee 97% uptime–the highest in the industry.”

It appears the Superchargers will also appear within the in-car nav during routing, so they’ll be publicly available to anyone who needs to use them. They are still available to all EVs that have worked with Tesla to utilize its infrastructure, and they are not restricted to people who are only visiting the business.

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Tesla reveals its Cybertruck light bar installation fix

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u/Kruzat, see page for license, via Wikimedia Commons

Tesla has revealed its Cybertruck light bar installation fix after a recall exposed a serious issue with the accessory.

Tesla and the National Highway Traffic Safety Administration (NHTSA) initiated a recall of 6,197 Cybertrucks back in October to resolve an issue with the Cybertruck light bar accessory. It was an issue with the adhesive that was provided by a Romanian company called Hella Romania S.R.L.

Tesla recalls 6,197 Cybertrucks for light bar adhesive issue

The issue was with the primer quality, as the recall report from the NHTSA had stated the light bar had “inadvertently attached to the windshield using the incorrect surface primer.”

Instead of trying to adhere the light bar to the Cybertruck with an adhesive, Tesla is now going to attach it with a bracketing system, which will physically mount it to the vehicle instead of relying on adhesive strips or glue.

Tesla outlines this in its new Service Bulletin, labeled SB-25-90-001, (spotted by Not a Tesla App) where it shows the light bar will be remounted more securely:

The entire process will take a few hours, but it can be completed by the Mobile Service techs, so if you have a Cybertruck that needs a light bar adjustment, it can be done without taking the vehicle to the Service Center for repair.

However, the repair will only happen if there is no delamination or damage present; then Tesla could “retrofit the service-installed optional off-road light bar accessory with a positive mechanical attachment.”

The company said it would repair the light bar at no charge to customers. The light bar issue was one that did not result in any accidents or injuries, according to the NHTSA’s report.

This was the third recall on Cybertruck this year, as one was highlighted in March for exterior trim panels detaching during operation. Another had to do with front parking lights being too bright, which was fixed with an Over-the-Air update last month.

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Tesla is already expanding its Rental program aggressively

The program has already launched in a handful of locations, specifically, it has been confined to California for now. However, it does not seem like Tesla has any interest in keeping it restricted to the Golden State.

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Credit: Grok

Tesla is looking to expand its Rental Program aggressively, just weeks after the program was first spotted on its Careers website.

Earlier this month, we reported on Tesla’s intention to launch a crazy new Rental program with cheap daily rates, which would give people in various locations the opportunity to borrow a vehicle in the company’s lineup with some outrageous perks.

Along with the cheap rates that start at about $60 per day, Tesla also provides free Full Self-Driving operation and free Supercharging for the duration of the rental. There are also no limits on mileage or charging, but the terms do not allow the renter to leave the state from which they are renting.

The program has already launched in a handful of locations, specifically, it has been confined to California for now. However, it does not seem like Tesla has any interest in keeping it restricted to the Golden State.

Job postings from Tesla now show it is planning to launch the Rental program in at least three new states: Texas, Tennessee, and Massachusetts.

The jobs specifically are listed as a Rental Readiness Specialist, which lists the following job description:

“The Tesla Rental Program is looking for a Rental Readiness Specialist to work on one of the most progressive vehicle brands in the world. The Rental Readiness Specialist is a key contributor to the Tesla experience by coordinating the receipt of incoming new and used vehicle inventory. This position is responsible for fleet/lot management, movement of vehicles, vehicle readiness, rental invoicing, and customer hand-off. Candidates must have a high level of accountability, and personal satisfaction in doing a great job.”

It also says that those who take the position will have to charge and clean the cars, work with clients on scheduling pickups and drop-offs, and prepare the paperwork necessary to initiate the rental.

The establishment of a Rental program is big for Tesla because it not only gives people the opportunity to experience the vehicles, but it is also a new way to rent a car.

Just as the Tesla purchasing process is more streamlined and more efficient than the traditional car-buying experience, it seems this could be less painful and a new way to borrow a car for a trip instead of using your own.

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