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SpaceX begins assembling first Starship Super Heavy booster in South Texas

SpaceX appears to have begun assembling Starship's first Super Heavy booster - set to be the largest in the world. (NASASpaceflight - bocachicagal)

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5 years ago

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SpaceX has taken the first unequivocal step towards orbital Starship launches, kicking off assembly of the first Super Heavy booster (first stage) – a necessity for recoverable spaceship missions to Earth orbit and beyond.

Although SpaceX could technically get away with building much smaller booster prototypes to support Starship’s initial orbital test flights, perhaps going as far as simply modifying Starship’s proven tank design, rocketry really doesn’t lend itself to modularity. Be it out of confidence or necessity, SpaceX appears to be moving directly from Starship prototype development to full-scale Super Heavy booster production and testing.

The first conveniently labeled Super Heavy booster rings were spotted around September 22nd. In the six or so weeks since then, SpaceX’s Boca Chica, Texas factory has relentlessly churned out at least as many sections of stacked booster rings – now strewn about the ever-growing campus. No less than seven labeled Super Heavy ring sections have been spotted since the first, equating to fewer than 25 steel rings of the estimated 38-40 needed to complete each booster.

The first Super Heavy rings – labeled “COMMON BARREL ASSY – BOOSTER” – were spotted on September 22nd. (NASASpaceflight – bocachicagal)
Six stacks of steel rings – all likely meant for the first Super Heavy – are pictured here on October 29th. (NASASpaceflight – bocachicagal)
On November 8th, SpaceX moved two stacks of four steel rings inside a custom Super Heavy assembly building within a few hours of each other. (NASASpaceflight – bocachicagal)

Relying on a tank design almost identical to hardware flight-proven on two separate Starship prototypes, SpaceX is able to use the exact same manufacturing infrastructure for the vast majority of Starship and Super Heavy. In fact, in a flip of the usual relationship, the next-generation rocket’s booster will most likely be far simpler than the upper stage – nominally the largest reusable spacecraft and upper stage ever attempted.

Without the need for a tiled heat shield, a conical nose section, aerodynamic control surfaces (beyond Falcon-style grid fins), or even (perhaps) internal header tanks, the only major challenge unique to Super Heavy is the development of an engine section capable of supporting and feeding as many as 28 Raptor engines. In other words, as long as the basics of Starship are successful and SpaceX is able to design a reliable 28-Raptor thrust structure and associated plumbing, Super Heavy may actually be a much easier problem to solve.

Theory aside, Starship and Super Heavy will unequivocally be the largest spacecraft, upper stage, and rocket booster ever built regardless of their success. While CEO Elon Musk recently stated that a Super Heavy booster could perform hop tests with just two Raptor engines, if necessary, the rocket is ultimately expected to have 20 high-thrust Raptors with minimal throttle capability and an inner ring of eight throttleable, gimballing engines for precision maneuvers.

With all 28 engines operating at full thrust, that particular Super Heavy design would produce an immense 6600 metric tons (14.5 million lbf) of thrust at liftoff – approximately twice the thrust of Saturn V and Soviet N-1 rockets and more than three times the thrust of SpaceX’s own Falcon Heavy. Measuring ~70m (~230 ft) tall, Super Heavy would weigh at least 3500 metric tons (7.7 million lb) fully loaded with liquid oxygen and methane propellant and – on its own – stand as tall or taller than Falcon 9, Falcon Heavy, and any other operational rocket on Earth.

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Now effectively inaugurated with the first Super Heavy booster (“BN1,” according to SpaceX) hardware, the ~83m (~270 ft) tall high bay will likely be in a near-constant state of activity as teams work to stack and weld the massive steel rocket. Essential to support Starship’s first recoverable orbital launch attempts, it remains to be seen how exactly SpaceX will put the first completed Super Heavy through its paces and what the first booster-supported Starship launches will look like. Regardless, barring major surprises during assembly, Super Heavy booster #1 (BN1) could be more or less complete just a month or two from now.

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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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SpaceX Starship gets FAA nod for ninth test flight

The FAA has given the green light for Starship’s ninth test flight.

Published

11 hours ago

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May 22, 2025

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(Credit: SpaceX)

SpaceX has received FAA approval for the ninth test flight of the Starship rocket. The approval was delayed due to the federal agency finishing its comprehensive safety review of the eighth flight earlier this year.

The FAA said in a statement that it has determined that SpaceX has “satisfactorily addressed the causes of the mishap, and therefore, the Starship vehicle can return to flight.”

The eighth test flight occurred back on March 6. SpaceX completed a successful liftoff of Starship and the Super Heavy Booster, before the two entered stage separation a few minutes after launch.

Starship Flight 8: SpaceX nails Super Heavy booster catch but loses upper stage

The booster returned and was caught by the chopsticks on the launch pad, completing the second successful booster catch in the program’s history. However, SpaceX lost contact with Starship in the upper atmosphere.

The ship broke up and reentered the atmosphere over Florida and the Bahamas.

The debris situation caused the FAA to initiate a mishap investigation:

The FAA said it will verify that SpaceX implements all the corrective actions on Flight 9 that it discovered during the mishap investigation.

There is no current confirmed launch window, but the earliest it could take off from Starbase is Tuesday, May 27, at 6:30 p.m. local time.

To prevent any injuries and potentially limit any damage, the FAA has stayed in contact with various countries that could be impacted if another loss of vehicle occurs:

“The FAA is in close contact and collaboration with the United Kingdom, Turks & Caicos Islands, Bahamas, Mexico, and Cuba as the agency continues to monitor SpaceX’s compliance with all public safety and other regulatory requirements.”

The agency has also stated that the Aircraft Hazard Area (AHA) is approximately 1,600 nautical miles and extends eastward from the Starbase, Texas, launch site through the Straits of Florida, including the Bahamas and Turks & Caicos.

For flight 8, the AHA was just 885 nautical miles.

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Hyundai begins real-world testing of AI-powered EV charging robot

Published

12 hours ago

on

May 22, 2025

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Credit: Hyundai

Hyundai announced on Thursday that it has officially launched real-world testing of its AI-powered EV charging robot, which it is referring to as the ACR.

The Korean company is partnering with both Kia and Incheon International Airport for the testing phase, which was launched with a memorandum of understanding (MOU). The pilot program is going to be used to lay the groundwork for future robot use for EV charging.

Incheon already has a reputation that aligns with the pilot program as it has the largest eco-friendly vehicle infrastructure in Korea, according to Korea JoongAng Daily, which first reported the launch of the pilot program.

Hyundai is partnering with Kia’s Robotics Lab to provide hardware and software solutions for this early rollout.

Yan Hee-won, President of Hyundai Motor’s R&D Division, said:

“This marks an important turning point in validating the practical value of future mobility technologies. With customized automatic charging solutions, we aim to deliver a more convenient and enhanced mobility experience for users.”

The testing phase will be limited in the sense that the charging robot will be deployed for a fleet of eco-friendly airport vehicles. Those who park their EVs at the airport will not be able to use it for use while they’re traveling — at least at first.

Eventually, it will become a great way to give vehicles range while the owners are off on trips.

Tesla had a similar idea several years ago, which it shared viral videos of back in 2015.

Tesla “snake charger” wasn’t just a creepy one-off, suggests Elon Musk

Musk said in 2020 that Tesla still had the intention of making it. However, it has shifted to wireless induction charging, which seems to be a better option simply because of fewer moving parts and better compatibility with the upcoming Robotaxi fleet.

Tesla flexes Robotaxi wireless charging — autonomy from top to bottom

Tesla displayed its wireless charging idea at the “We, Robot” event last year:

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How Tesla could benefit from the ‘Big Beautiful Bill’ that axes EV subsidies

Tesla has a few paths to limit damage from the elimination of tax credits.

Published

14 hours ago

on

May 22, 2025

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President Donald J. Trump purchases a Tesla on the South Lawn, Tuesday, March 11, 2025. (Official White House Photo by Molly Riley)
President Donald J. Trump purchases a Tesla on the South Lawn, Tuesday, March 11, 2025. (Official White House Photo by Molly Riley)

The United States House of Representatives passed President Trump’s “Big Beautiful Bill” by a vote of 215 to 214 on Thursday, effectively bringing an end to many EV subsidy programs, like the $7,500 tax credit, by the end of this year.

The bill will not only eliminate the $7,500 credit on new EV purchases, but also the $4,000 credit given on the purchase of used electric vehicles, and a $1,000 credit on the installation of Level 2 chargers. It will also impact solar subsidies that help generate clean energy in a residential setting.

EVs would also be subject to a $250 road use fee.

All of these things sound like negatives — truly because they are. Those who are not in a financial position to buy an EV this year, even with the tax credit, might not be able to afford them in the coming years either, unless manufacturers are able to bring pricing to a level that is more accessible to consumers.

In theory, President Trump’s focus on bringing manufacturing back to America would bring prices down, but it won’t happen overnight. Companies will take many years to completely bring manufacturing and part sourcing to the United States.

However, Tesla could feel some positives from this bill, and it all comes down to timing. Of course, in the long term, it wouldn’t be great for the company, especially if it did not have two things going on right now: a slightly lagging delivery pace and the introduction of affordable models.

Tax Credit Sunsetting Advantage

Sunsetting the $7,500 tax credit means one thing: those who have been in limbo over buying an EV from Tesla are going to have to make a decision on whether they want to buy this year and still have access to the credit, or test their luck and hope for price reductions.

More than likely, those who have been on the fence will be willing to pull the trigger this year, and Tesla will definitely gain some sales from this fact alone. Other automakers will, too.

This could help offset Tesla’s slow start to the year, which has been caused by the changeover of production lines of the Model Y across each of its factories globally.

Affordable Models

Tesla said earlier this year that it will roll out affordable models in the first half of 2025. These cars are expected to be around the $30,000 mark, but the company has not shed any true information on what they will cost.

Potential affordable Tesla “Model 2/Model Q” test car spotted anew in Giga Texas

Ideally, the cars would cost under $30,000 without the EV tax credit, which would be more than accessible for many car buyers in the United States.

The introduction of models that are not in need of a tax credit to be affordable to the masses. This would help offset some of the losses Tesla might feel from cars losing the tax credit.

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