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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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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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Elon Musk says Tesla will take Safety Drivers out of Robotaxi: here’s when

“The safety driver is just there for the first few months to be extra safe. Should be no safety driver by end of year.”

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Credit: Joe Tegtmeyer | X

Tesla CEO Elon Musk said today that the company plans to completely eliminate Safety Drivers from its Robotaxi fleet, which differs from the Safety Monitors it uses.

Tesla’s Robotaxi platform utilizes employees in the front passenger seat during city rides in Austin and the driver’s seat of the vehicles during highway operations in Austin, as well as during all rides in the Bay Area.

Tesla adjusts Robotaxi safety monitor strategy in Austin with new service area

Musk said the presence of a Safety Driver “is just there for the first few months to be extra safe,” but there are plans to remove them in an effort to remove the crutches the company uses during the early stages of Robotaxi.

The CEO then outlined a timeframe for when it would remove the presence of an employee in the driver’s seat in both Austin and the Bay Area. He said there “should be no safety driver by end of year.”

Having a Safety Driver or Monitor has been a major point of criticism from Robotaxi skeptics and Tesla critics.

However, Tesla has maintained that its priority in the early stages is the safety of riders, which will keep things running; even a single negative incident could derail self-driving efforts as a whole, including those outside of the company.

Tesla executives have said their attitude toward safety is “paranoid,” but for good reason: an accident could set back the progress that it and many other companies, including rivals like Waymo, have made in the past few years.

For now, it might be a point of criticism for some, but it’s smart in the near term. Musk plans for Tesla to have Robotaxi operating for half of the U.S. population by the end of the year as well, so it will be interesting to see if it can maintain these timelines.

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Tesla is already giving Robotaxi privileges hours after opening public app

This morning, Tesla launched the app in the Apple Store, giving iOS users the ability to download and join a waitlist in hopes of gaining access.

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tesla robotaxi app on phone
Credit: Tesla

Tesla is already giving Robotaxi privileges to those who downloaded the app and joined its waitlist just hours after it launched in the United States.

As the Robotaxi platform has been operating in Austin for several months, Tesla is now allowing the general public to download its app and call for a driverless ride in the city.

Tesla Robotaxi makes major expansion with official public app launch

The company previously sent invitations to select media outlets and Tesla influencers, seeking initial feedback on the performance of the Robotaxi platform.

There have been positive reviews, but, as with any Beta program, some mishaps have also occurred, although none have been significant.

As of the writing of this article, the City of Austin only lists one incident involving a Tesla Robotaxi, noting it as a “Safety Concern,” but not an accident or collision.

This morning, Tesla launched the app in the Apple Store, giving iOS users the ability to download and join a waitlist in hopes of gaining access.

Tesla is already granting Robotaxi access to several of those who have downloaded the app and gotten on the waitlist early:

With the launch of the public app, we were not too sure how soon Tesla would be able to initiate bringing more riders into the Robotaxi program. The immediate admittance for some riders just hours after the launch is a big positive and is surely a sign of strength for Tesla and its Robotaxi program.

What many will look for moving forward is the expansion of the geofence, which does not seem like a problem, as Tesla has already managed to do this on three occasions. The most recent expansion has expanded the service area to approximately 190 square miles.

People will also look for evidence of fleet expansion, a concern that has been a concern for many, especially since Tesla has not been completely transparent about it. They have revealed a recent service fleet growth of 50 percent, but there has been no specific number of vehicles mentioned.

Tesla reveals it has expanded its Robotaxi fleet in Austin

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Tesla explains why Robotaxis now have safety monitors in the driver’s seat

The update to Austin’s safety monitors became a point of interest among Tesla watchers on social media.

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Credit: Tesla

Tesla has provided an explanation about the presence of safety monitors in the driver’s seat of its autonomous Robotaxi units.

The autonomous ride-hailing service is currently being deployed in Austin and the Bay Area, with more cities across the United States expected to gain access to the service later this year.

Safety Monitors

When Tesla launched its initial Robotaxi program in Austin, the company made headlines for operating vehicles without a human in the driver’s seat. Even with this setup, however, Tesla still had safety monitors in the passenger seat of the Robotaxis. The safety monitors, which do not interact with passengers, have been observed to report issues and other behaviors from the autonomous vehicles in real time. 

Safety monitors on the driver’s seat were also employed in the service’s Bay Area rollout, though numerous members of the EV community speculated that this was likely done to meet regulations in California. However, with the expansion of the Austin geofence, riders in Tesla’s Robotaxis observed that the safety monitors in the city have been moved to the driver’s seat as well.

Tesla’s explanation

The update to Austin’s safety monitors became a point of interest among Tesla watchers on social media. Longtime FSD tester Whole Mars Catalog, for one, speculated that the move might be due to Texas’ new regulations for autonomous vehicles, which took effect recently. Interestingly enough, the official Tesla Robotaxi account on X responded to the FSD tester, providing an explanation behind the safety monitor’s move to the driver’s seat. 

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“Safety monitors are only in the driver’s seat for trips that involve highway driving, as a self-imposed cautious first step toward expanding to highways,” the Tesla Robotaxi account noted.

Tesla has been extremely cautious with its autonomous driving program, particularly with the rollout of its Robotaxi service, which use Unsupervised FSD. This is quite understandable considering the negative media slant that Tesla is consistently subjected to, which could very well result in minute incidents or mistakes by Robotaxis being blown out of proportion.

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