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SpaceX to shrink, tweak Starship’s forward flap design, says Elon Musk

Elon Musk says that SpaceX is redesigning Starship's forward flaps. (NASASpaceflight - bocachicagal)

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4 years ago

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SpaceX CEO Elon Musk says that there is a “slight error” with the current design of Starship’s forward flaps, necessitating a few small but visible changes on future prototypes of the spacecraft.

Measuring 9m (30 ft) wide and approximately 50m (~165 ft) from tip to tail, Starship is the combined upper stage, spacecraft, tanker, and lander of a two-stage, fully-reusable rocket with the same name. While SpaceX has a long ways to go to achieve it, the company’s ambition is for Starship and its Super Heavy booster to be the most easily and quickly reusable spacecraft and rocket booster ever built, nominally enabling the same-day reuse of both.

Beyond a Space Shuttle-style heat shield of blankets and ceramic tiles, the Starship upper stage is meant to achieve that reusability by descending through the atmosphere and landing unlike any other spacecraft, plane, or rocket ever flown. Instead of flying, gliding, or knifing through the atmosphere nose or tail-first, Starship freefalls perpendicular to the ground for the last few dozen kilometers (~10-20 mi) before aggressively flipping into a vertical orientation at the last second and landing propulsively on its tail. Now, according to Elon Musk, two of the four ‘flaps’ that largely make that exotic maneuver possible are set for a small but significant redesign.

Over the course of five suborbital test flights of full-scale Starship prototypes completed between December 2020 and May 2021, SpaceX took that exotic landing concept from the drawing board and subscale wind tunnel testing to reality. Though four of those five tests ended in destruction, their respective Starship prototypes really only failed in the last 15-30 seconds of test flights that were more than six minutes long.

After reaching an apogee of 10-12.5 km (~6.2-7.8 mi) over the course of some four and a half minutes, all five Starship prototypes successfully shut down their Raptor engines, tipped over onto their bellies, and then used a combination of small pressurized gas thrusters and four large flaps to stably fall back to Earth. Much like a skydiver can tweak their body, arms, and legs to control their orientation and attitude, Starship uses two pairs of forward and aft flaps to achieve a very similar level of control.

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Thanks to Starship’s significant surface area and relatively low mass shortly before landing, that unprecedented freefall-style descent naturally slows the rocket to just 100-200 mph (~50-100 m/s) while simultaneously allowing SpaceX to avoid the massive complexity and added mass of structural wings or fins like those on the Space Shuttle. Further, whereas the Shuttle used its wings to glide (albeit like a brick) and land on very long runways, Starship is designed to use three of its six Raptor engines to flip into a vertical orientation and land much like SpaceX’s own spectacularly successful Falcon boosters.

During the actual process of reentry, in which Starship uses a heat shield made up of ~15,000 ceramic tiles to slow from orbital (Mach 25 or ~7.5 km/s) to subsonic speeds, those same flaps also come in useful to control the vehicle’s angle of attack and thus the degree of extreme heating experienced. According to Musk, to improve the moment arm (i.e. leverage or, all else equal, torque) of Starship’s forward flaps and reduce or remove undesirable aerodynamic characteristics, SpaceX is going to shrink those forward flaps further, move them closer together and more towards the tip of Starship’s nose, and angle them toward the ship’s leeward side (back).

Apparently, those relatively minor changes mean that a portion of Starship’s forward flaps will no longer be directly subjected to reentry heating, potentially allowing SpaceX to entirely remove static “aerocovers” that wrap around the ship’s flaps to prevent superheated plasma and gas from reaching sensitive components. Ironically, SpaceX’s thermal protection team completed the installation of heat shield tiles on one of those forward flap aerocovers for the first time ever just a few days ago – a structure and portion of heat shield that will apparently no longer be needed on future Starships.

For now, though, it looks like Ship 20 will attempt Starship’s first orbital launch with its now-outdated forward flaps. Depending on how far along Ship 21 production is, the next prototype could feasibly sport that new flap design.

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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 schedules Roadster unveiling event, and you won’t believe when it is

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41 minutes ago

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November 6, 2025

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Tesla has tentatively scheduled its unveiling event for the Roadster’s next-generation iteration, and you will not believe the date the company picked for it.

Tesla CEO Elon Musk said during the 2025 Annual Shareholders Meeting that the company is aiming for an April 1 demo event.

Yes, April Fools’ Day.

Tesla originally aimed for its “most epic demo” to take place at the end of this year. However, the writing on the wall as 2025 winds down seemed to indicate the company was not quite ready to show off everything it plans to implement into the Roadster.

Its capabilities have been teased quite heavily throughout most of the year, but the biggest hints came last week when Musk appeared on the Joe Rogan Experience Podcast.

He said:

“Whether it’s good or bad, it will be unforgettable. My friend Peter Thiel once reflected that the future was supposed to have flying cars, but we don’t have flying cars. I think if Peter wants a flying car, he should be able to buy one…I think it has a shot at being the most memorable product unveil ever. [It will be unveiled] hopefully before the end of the year. You know, we need to make sure that it works. This is some crazy technology in this car. Let’s just put it this way: if you took all the James Bond cars and combined them, it’s crazier than that.”

The Roadster has been somewhat of a letdown, at least in its newest version, thus far. Tesla has routinely delayed the project, putting those who put lofty down payments on the car in a weird limbo, lost at what to do.

One notable pre-orderer cancelled his reservation last week and got in a spat with Musk about it.

Now that there is a definitive date for the Roadster unveiling, Musk and Co. should have a more definitive cutoff date for features and capabilities. Chief Designer Franz von Holzhausen said earlier this year that when they showed Musk what they had done with the Roadster, the CEO encouraged them to do even more with it.

This delayed things further.

Musk also said he believes production would begin between 12 and 18 months after the unveiling, putting it out sometime in 2027.

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Elon Musk

Tesla (TSLA) shareholders officially approve Elon Musk’s 2025 performance award

To earn his landmark pay package, Musk would be required to lift Tesla’s market capitalization from about $1.1 trillion today to $8.5 trillion over the next decade.

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2 hours ago

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November 6, 2025

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Justin Pacheco, Public domain, via Wikimedia Commons

Tesla (NASDAQ:TSLA) CEO Elon Musk has officially approved his 2025 Performance Award, a landmark pay package that could make him the world’s first trillionaire and make Tesla the most valuable company in the world by a mile. 

The 2025 CEO Performance Award was officially approved by Tesla shareholders at the 2025 Annual Shareholder Meeting.

Elon Musk‘s landmark pay package

As per Tesla, more than 75% of the shareholders approved Elon Musk’s 2025 CEO Performance Award. It was then unsurprising that the approval of Elon Musk’s pay plan received overwhelming applause from the event’s attendees.

The CEO took to the stage with much enthusiasm, welcoming every shareholder to the event and dancing briefly on stage. Optimus also danced on stage smoothly, demonstrating its improved movements to much appause.

Elon Musk’s 10-year targets

To earn his 2025 CEO Performance Award, Musk would be required to grow Tesla’s market capitalization from about $1.1 trillion today to $8.5 trillion over the next decade. At that level, Tesla would surpass every major public company in existence. The compensation plan also requires Tesla’s operating profit to grow from $17 billion last year to $400 billion annually. 

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Apart from leading Tesla to become the world’s biggest company in history, Musk is also required to hit several product targets for the electric vehicle maker. These include the delivery of 20 million Tesla vehicles cumulatively, 10 million active FSD subscriptions, 1 million Tesla bots delivered, and 1 million Robotaxis in operation.

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Elon Musk

Tesla 2025 Annual Shareholder Meeting: How to watch

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4 hours ago

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November 6, 2025

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Credit: @YunTaTsai1 | X

The 2025 Tesla Annual Shareholder Meeting from Gigafactory Texas is set to kick off at 4 p.m. EDT, 3 p.m. CDT.

The company will be having its typical presentation for the event, where CEO Elon Musk, along with other executives will discuss things like future products, the outlook of its self-driving development, potential releases for next year, and some current events within the company.

However, this year’s Shareholder Meeting has slightly more implications than others, as Investors and Shareholders have spent the last several months petitioning and supporting one of the proposals on the docket that could be the deciding factor in Musk staying or leaving Tesla.

Elon Musk’s new pay plan ties trillionaire status to Tesla’s $8.5 trillion valuation

Proposal four outlines a new compensation package for Musk that could give him $1 trillion in shares if he is able to complete a variety of lofty goals related to production, self-driving, and other important company projects.

Musk has said that he is truly after more influence on company decisions, especially as the Tesla Optimus program is ramping up and becoming a more relevant part of the company’s story.

The CEO said during the Q3 Earnings Call that he would not feel comfortable developing an “army of robots” if he did not have a comfortable amount of influence in some of the decisions. He could be voted our or out-influenced by what he calls “activist shareholders.”

One of those investors came after his past pay package, which was approved by shareholders not once, but twice. Musk still was not able to obtain the pay because of a Delaware Chancery Court ruling.

Nevertheless, this is one of the last ditch efforts Tesla is making to get Musk the compensation that he wants.

The meeting is set to kick off at 3 p.m. local time in Austin. You can watch it via the livestream on X:

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