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SpaceX fully stacks Starship rocket for the first time in six months

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For the first time in more than six months, SpaceX has stacked both stages of its next-generation Starship rocket, creating the largest and most powerful launch vehicle ever fully assembled.

It’s not the first time. SpaceX has conducted three other ‘full-stack’ Starship demonstrations: once in August 2021 and again in February and March 2022. But earlier this year, SpaceX (or at least CEO Elon Musk) decided to give up on the Starship upper stage and Super Heavy booster prototypes that had supported all three of those prior tests and, at one point, been considered a candidate for the rocket’s first orbital launch attempt. Booster 4 and Ship 20 were consigned to a retirement yard by June 2022.

By then, SpaceX had already begun testing the new favorites for Starship’s orbital launch debut: Super Heavy Booster 7 (B7) and Starship 24 (S24). Almost exactly six months after the start of that busy period of testing, both prototypes recently reached the point where SpaceX was confident enough in their progress to combine the two for the most challenging phase of Starship testing yet.

After an aborted predawn attempt on October 11th, SpaceX technicians worked out some mystery kinks in crucial infrastructure located at Starship’s first (nearly) finished orbital launch pad in Boca Chica, Texas. As part of a cart-before-horse gamble made by CEO Elon Musk that has seen SpaceX entirely remove legs from all recent Starship and Super Heavy prototypes in the hope that it will one day be able to catch the building-sized rocket stages out of mid-air, the company has built a launch tower ~145 meters (~475 ft) tall and outfitted it with three giant robotic arms. Two of those arms are identical and linked together, forming a sort of claw that could one day close around hovering rockets to preclude the need for landing legs. A simpler third arm swings in and out to connect Starship’s upper stage to the launch pad’s power, propellant, and gas supplies.

The ‘chopsticks,’ as they’re known, have another even more important purpose: assembling Starship rockets at the launch pad. Thanks to their sturdy connection to a tower with a foundation sunk deep into the Boca Chica wetlands and a design that forgoes a hanging hook or jig for giant arms, they are far less sensitive to winds than the immense crane otherwise required to stack Starship on top of Super Heavy. Sitting a stone’s throw from the Gulf of Mexico, storms and high winds are not exactly uncommon.

Around sunset on October 11th, SpaceX had better luck on its third attempt and was able to move the arms into place under Ship 24. Weighing 100 tons or more (~220,000+ lb) and measuring nine meters (~30 ft) wide and ~50 meters (~165 ft) tall, the Starship was then slowly lifted about 80 meters (~250 ft) off the ground, translated over to Booster 7, and lowered on top of the 69-meter-tall (~225 ft) first stage. After about two more hours of robotically tweaking their positions, the two Starship stages were finally secured together. With the arms still attached to Ship 24, SpaceX workers were able to approach the rocket and prepare to connect the swing arm’s quick-disconnect umbilical to Starship.

Ship 24 and Booster 7 have both completed several major tests to date. (SpaceX)

Since they began qualification testing in April and May 2022, Booster 7 and Ship 24 have each completed several cryogenic proof tests, eight ‘spin-primes’ of some or all of their Raptor engines, and several static fires of those same engines. Most recently, Ship 24 ignited all six of its Raptors, but the seemingly successful September 8th test was followed by more than a month of apparent repairs. Booster 7 last completed a static fire that ignited a record seven of its 33 Raptor engines – offering an idea of how much further SpaceX still has to go to finish testing the Super Heavy.

According to CEO Elon Musk, Booster 7 and Ship 24 will attempt Starship’s first full-stack wet dress rehearsal (WDR) once all is in order. The prototypes will be simultaneously loaded with around 5000 tons (~11M lb) of liquid oxygen and methane propellant and then run through a launch countdown. Diverging just before ignition and liftoff, a WDR is meant to be more or less identical to a launch attempt.

If the wet dress rehearsal goes to plan, SpaceX will then attempt to simultaneously ignite all 33 of the Raptor engines installed on Super Heavy B7, almost certainly making it the most powerful liquid rocket ever tested. Even if all 33 engines never reach more than 60% of their maximum thrust of 230 tons (~510,000 lbf), they will likely break the Soviet N-1 rocket’s record of 4500 tons of thrust (~10M lbf) at sea level. It would also be the most rocket engines ever simultaneously ignited on one vehicle. SpaceX will be pushing the envelope by several measures, and success is far from guaranteed.

It’s unclear if SpaceX will immediately attempt a full wet dress rehearsal or 33-engine static fire. Based on the history of Ship 24 and Booster 7 testing, it would be a departure from the norm if the company doesn’t slowly build up to both major milestones with smaller tests in the interim. At minimum, assuming WDR testing is completed without major issue, SpaceX will likely attempt at least one or more interim static fires with fewer than 33 engines before attempting the first full test.

If both milestones (a full WDR and 33-engine static fire) are completed without significant issue, there’s a chance that SpaceX could move directly into preparations for Starship’s first orbital launch attempt without unstacking the rocket. In the likelier scenario that some issues arise and some repairs are required, the path will be more circuitous but should still end in an orbital launch attempt late this year or early next.

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Booster 7’s 33 Raptor V2 engines. (SpaceX)
Mechazilla’s third successful Starship stack. (SpaceX)

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 Semi’s biggest adoptee gives an update on production timeline

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Credit: Tesla

Tesla recently received its largest order for the all-electric Semi from Einride, a Swedish transport service, for 500 units, a groundbreaking invoice to receive before the first deliveries begin.

Even more remarkable, Einride CEO Roozbeh Charli said in a recent interview that he expects his company to take delivery of all 500 — the entire order — before the end of 2027. He even expects to have 75 Tesla Semi units in the Einride fleet before the end of this year.

Charli said the Tesla partnership was part of a broader push, along with its earlier partnership with Amazon. Einride is assisting Amazon with the use of its Saga AI platform, which helps eliminate questions about budgeting and forecasting for logistics companies.

The Semi, as well as Tesla’s production and subsequent delivery of the units to Einride, will help the company “to have a good supply of vehicles that we can deploy on the [Saga AI] platform,” Charli said. “Tesla is also a relationship we’ve had for a while, and as the Tesla Semi deliveries are firming up, we decided to do a larger commitment to that and deploy that on our platform.”

In its initial announcement, Einride said it anticipated taking delivery of the trucks over the next two years, but now it appears the company is expecting all 500 units within the next 16 months.

Tesla Semi gets its largest order yet

Built at a dedicated factory in Sparks, Nevada, the Tesla Semi has been perhaps the biggest and most intensive testing process the company has ever had for a single vehicle model. For the past several years, Tesla has been working with many companies, most notably Frito-Lay and PepsiCo, to gain knowledge on the performance on regional routes.

Tesla plans to launch the Semi officially on September 24, five months after production started ramping.

Additionally, drivers have said they are happy about the Semi’s performance and that its numerous safety and productivity features have made their jobs and routes much easier.

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Tesla Cybercab uses a unique strategy for picking up the right rider

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Credit: ARTSIMAGE | X

Tesla Cybercab is using a unique strategy for picking up the correct rider, which is a crucial part of ride-hailing to ensure people end up in the right place and are charged the correct price.

Cybercab will utilize an RGB strip in its front light bar that will illuminate in a variety of different colors to mark itself.

This identifying mark will also appear in the Robotaxi app, giving riders in the same location a notable distinction in an effort to avoid any confusion regarding who should get in each vehicle.

Other ride-hailing services use similar strategies: Lyft and Uber rides are recognizable through driver identity, vehicle type and color, as well as license plate. Waymo will display the rider’s initials on top of the vehicle, letting them know that the specific vehicle for them has arrived.

Tesla’s strategy is unique and interesting, but there are some flaws. Cybercab’s main purpose is aimed toward being an autonomous ride for all, including those who have disabilities like being blind or even color blind.

Tesla will likely have something in the pipeline for those who cannot see colors or have limited vision. There will definitely be multiple ways to identify which vehicle is the one that “you” specifically ordered.

Cybercab is set to start giving public rides next Thursday, September 3, in Austin, as it announced a dedicated event last week and invited many members of the Tesla community.

Tesla will launch Cybercab on September 3

Additionally, members of the public will be invited as well. Tesla has been offering employee rides in Cybercab for nearly two months.

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Tesla ends in-house wrap service that always seemed like a short-term program

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Credit: Tesla

Tesla has said goodbye to one customization option for its vehicles: the wrap service it launched several years ago.

After launching an in-house wrap service in August 2020 for the first time in China. In the U.S., it launched in October 2023. Tesla continued to expand the program and adjust it with better pricing and fewer options for the Cybertruck.

By December 2023, it was giving owners of the Model 3, Model Y, and the Cybertruck the opportunity to give their vehicle a fresh look with a vinyl wrap.

Tesla revamps in-house vinyl wrap service with better pricing

It was only available in five locations: Costa Mesa, Oceanside, Santa Clara, West Covina, all in California, and Seattle, Washington.

However, Tesla made some big adjustments to its shop, and the wrap service is officially gone:

Wraps are very popular across the Tesla lineup, especially since the company offers relatively few colors. Many choose to wrap their Teslas with interesting colors, patterns, or even finishes, turning their cars from glossy to satin or matte.

However, Tesla’s wrap service was so limited geographically that it never really had a chance to get off the ground or compete with local shops. Every area in the United States is now overflowing with detailing shops, mobile detailers, and other automotive specialists, many of whom perform wrap services.

Tesla’s service was confined to the Pacific time zone and only spanned across two states. It was never going to be something Tesla was a major competitor in, nor was it going to disrupt the wrapping industry. Now that the program has ended, it seems pretty ideal to believe it was always going to be a short-term thing.

Along with the wrap service, Tesla removed several other products, but nothing too crazy. The Model 3 Door Pocket and Cupholder Liners, the Model S 19″ Magnetite Wheel and Winter Tire Package, Model X/Y Ski/Snowboard Carrier for Hitch Rack, Tesla’s Electric Summer Party Tee, and the Electric Summer Tee were the other items the company totally eliminated from its online shop.

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