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SpaceX’s first orbital Starship rocket engine is almost ready for testing

Elon Musk says that SpaceX could be just a month away from testing the first Raptor Vacuum (RaptorVac) engine, three of which are pictured burning in this Starship render. (SpaceX)

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CEO Elon Musk says that SpaceX is “about a month away” from testing a rocket engine that will be essential for Starship and its Super Heavy booster to reach their full potential.

Known as Raptor Vacuum, the engine – as its name suggests – is a variant of the base Raptor engine optimized for maximum performance and efficiency in the vacuum of space. Although Starship could technically still function and likely reach orbit with only sea level-optimized Raptors installed, it would likely significantly limit the amount of payload it could carry into Earth orbit and would especially harm the ship’s performance to higher orbits and other planets.

Back in May 2019, Musk revealed that SpaceX had shifted gears again, forgoing a plan to begin orbital Starship flight operations with only sea level Raptors, gradually designing and phasing in RaptorVac engines much further down the road. Instead, SpaceX restarted (relatively) urgent work on the vacuum variant and Musk hinted that it would “aspirationally” be ready to support launches in the near term. A few weeks shy of a year later, Musk says that Raptor Vacuum testing could begin as early as June 2020.

A 2016 render of Raptor Vacuum. Much has changed about the engine’s design in the three years since, but SpaceX is still pursuing a vacuum variant. (SpaceX)

For a variety of reasons, even if based directly off of an existing design, vacuum-optimized engines are typically much more complex than a comparable sea level variant. While efficiency is always relatively important for rocket engine design, it becomes even more paramount when dealing with vacuum rocketry, as the entire point of a dedicated vacuum-optimized engine is to eke as much efficiency as possible out of a launch vehicle’s orbital stage(s).

A visual comparison of Merlin 1D (optimized for sea level) and Merlin Vacuum. (SpaceX)

For example, even from a purely visual perspective, Merlin Vacuum (MVac) is substantially different when compared to the Merlin 1D engine it’s based on. Due to a number of major and largely unknown differences, the engines’ shared components are largely invisible. It’s unclear how similar they are but it’s safe to say that they share at least ~50% commonality. Obviously, the most apparent part of the difference between a vacuum-optimized engine and an atmosphere-optimized engine is the bell nozzle: MVac has a nozzle that is dramatically larger than M1D.

Raptor will be no different, with the sea-level variant featuring a nozzle about 1m (3.2 ft) in diameter, whereas RaptorVac’s bell will have a diameter closer to 2.5m (~8 ft). With SpaceX’s apparent May 2019 pivot back to working on RaptorVac now, the company has been working on a dedicated vacuum variant of the high-performance methane-oxygen engine for at least a full year. Now, perhaps beginning as early as June or July, Musk suggests that the first RaptorVac engine (SN0? SN1?) is almost ready to commence static fire testing.

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A Falcon 9 upper stage’s vacuum nozzle glows white hot during an orbital MVac burn. (SpaceX)
SpaceX technicians wrench on a Merlin Vacuum D (MVacD) engine. (SpaceX)
Raptor performs a static fire test in McGregor, Texas. (SpaceX)

The nature of that testing is a bit of a mystery. While it will almost certainly occur at SpaceX’s McGregor, Texas test and development facilities, it’s unclear if Raptor Vacuum’s first static fire test campaign will be attempted with the engine’s extended nozzle installed. Back in October 2019, Musk suggested that yes, Raptor Vacuum version 1.0 would have a nozzle small enough to operate at sea level without destroying itself or its test facilities. With Merlin Vacuum engines, SpaceX performs acceptance tests in Texas but only without their nozzle extensions installed. If Musk’s October 2019 comments remain true, that may not be the case for RaptorVac.

Either way, it will be thoroughly interesting to note the differences between RaptorVac and its sea level-optimized predecessor if or when Elon Musk or SpaceX releases photos of their newest engine as it nears its first major tests. Simultaneously, SpaceX is also readying a sea-level Raptor for its inaugural static fire test while attached to a full-scale Starship prototype, while the first test with three Raptor engines installed could be attempted just a few weeks from now.

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 VP explains latest updates in trade secret theft case

Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

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tesla 4680
Credit: Tesla Inc.

Tesla Vice President Bonne Eggleston explained the latest updates in a trade secret theft case the company has against a former manufacturing equipment supplier, Matthews International.

Back in 2024, Tesla had filed a lawsuit against Matthews International, alleging that the firm stole trade secrets about battery manufacturing and shared those details with some of Tesla’s competitors.

Early last year, a U.S. District Court Judge denied Tesla’s request to block Matthews International from selling its dry battery electrode (DBE) technology across the world. The judge, Edward Davila, said that the patent for the tech was due to Matthews’ “extensive research and development.”

Tesla is suing a former supplier for trade secret theft

The two companies’ relationship began back in 2019, as Tesla hired Matthews to help build the equipment for its 4680 battery cell. Tesla shared confidential software, designs, and know-how under strict secrecy rules.

Fast forward a few years, and Tesla reportedly caught Matthews copying the tech into machines that were sold to competitors, claiming they lied about doing so for three years, and continued to ship it. That is when Tesla chose to sue Matthews in July 2024 in Federal court, demanding over $1 billion in damages due to trade secret theft.

Now, the latest twist, as this month, a Judge issued a permanent injunction—a court order banning Matthews from using certain stolen Tesla parts or designs in their machines. Matthews is also officially “liable” for damages. The exact amount would still to be calculated later.

Bonne Eggleston, a VP for Tesla, said on X today that Matthews is a supplier who “exploited customer IP through theft or deception,” and has no place in Tesla’s ecosystem:

Tesla calls this a big win and warns other companies: “Buyer beware—don’t buy from thieves.”

Matthews hit back with a press release claiming victory. They say an arbitrator ruled they can keep selling their own DBE equipment to anyone and rejected Tesla’s request for a total sales ban. They call Tesla’s claims “nonsense” and insist their 20-year-old tech is independent. Both sides are spinning the same narrow ruling: Matthews can sell their version, but they’re blocked from using Tesla’s specific secrets.

What are Tesla’s Current Legal Options

The case isn’t over—it’s moving to the damages phase. Tesla can:

  • Push forward in court or arbitration to calculate and collect huge financial penalties (potentially $1 billion+ if willful theft is proven).
  • Enforce the permanent injunction with contempt charges, fines, or even jail time if Matthews violates it.
  • Challenge Matthews’ new patents that allegedly copy Tesla’s work, asking courts to invalidate them or add Tesla as co-inventor.
  • Seek extra damages, lawyer fees, and possibly punitive awards under the federal Defend Trade Secrets Act and California law.

Tesla could also refer evidence to federal prosecutors for possible criminal trade-secret charges (rare but serious). Settlement is always possible, but Tesla’s fiery public response suggests they want full accountability.

This isn’t just corporate drama. It shows why trade secrets matter even when Tesla open-sources some patents, confidential know-how shared in trust must stay protected. For the EV industry, it’s a reminder: steal from your biggest customer, and you risk losing everything.

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Tesla Cybercab includes this small but significant feature

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

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Credit: Tesla

Tesla Cybercab manufacturing is strikingly close, as the company is still aiming for an April start date. But small and significant features are still being identified for the first time as production units appear all over the country for testing and for regulatory events, like one yesterday in Washington, D.C.

The Cybercab is Tesla’s big plan to introduce fully autonomous ride-sharing in a seamless fashion. In fact, the Full Self-Driving suite was geared toward alleviating the need to manually drive vehicles.

This was for everyone, including the disabled, who are widely reliant on ride-sharing platforms, family members, and medical shuttles for transportation of any kind. Cybercab aims to change that, and Tesla evidently put a focus on those riders while developing the vehicle, evident in a small but significant feature revealed during its appearance in the Nation’s Capital.

Tesla Cybercab display highlights interior wizardry in the small two-seater

Tesla has implemented Braille within the Cybercab to make it easier for blind passengers to utilize the vehicle. On both the ‘Stop/Hazard Lights’ button and the Door Releases, Tesla has placed Braille so that blind passengers can navigate their way through the vehicle:

This is a great addition to the Cybercab, especially as Full Self-Driving has been partially pointed at as a solution for those with disabilities that would keep them from driving themselves from place to place.

It truly is a great addition and just another way that Tesla is showing they are making this massive product inclusive for everyone out there, including those who have not been able to drive due to not having vision.

The Cybercab is set to enter mass production sometime in April, and it will be responsible for launching Tesla’s massive plans for an autonomous ride-sharing program.

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Tesla and xAI team up on massive new project

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

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Credit: Grok

Elon Musk teased a massive new project, to be developed jointly by Tesla and xAI, called “Digital Optimus” or “Macrohard,” the first development under Tesla’s investment agreement with xAI.

Musk announced on X that Digital Optimus will “be capable of emulating the function of entire companies.”

It is the latest move by a Musk company to automate, streamline, and reduce the manual, monotonous, and tedious work currently performed by humans through AI and robotics development. Digital Optimus will be capable of processing and actioning the past five seconds of a real-time computer screen video and keyboard and mouse actions.

Essentially, it will be an AI version of a desk worker in many capacities, including accounting, HR tasks, and others.

Musk said:

“Grok is the master conductor/navigator with deep understanding of the world to direct digital Optimus, which is processing and actioning the past 5 secs of real-time computer screen video and keyboard/mouse actions. Grok is like a much more advanced and sophisticated version of turn-by-turn navigation software. You can think of it as Digital Optimus AI being System 1 (instinctive part of the mind) and Grok being System 2. (thinking part of the mind).”

Its key applications would be used for enterprise automation, simulating entire companies, high-volume repetitive tasks, and potentially, future hybrid use with the Optimus robot, which would handle physical tasks, while Digital Optimus would handle the clerical work.

Tesla announces massive investment into xAI

The creation of a digital AI suite like Digital Optimus would help companies save time and money, as well as become more efficient in their operations through massive scalability. However, there will undoubtedly be concerns from people who are skeptical of a fully-integrated AI workhorse like this one.

From an energy consumption perspective and just a general concern for the human workforce, these types of AI projects are polarizing in nature.

However, Digital Optimus would be a great digital counterpart to Tesla’s physical Optimus robot, as it would be a hyper-efficient addition to any company that is looking for more production for less cost.

Musk maintains that there is no other company on Earth that will be able to do this.

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