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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)

Published

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 plant manager tips off affordable model production

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6 hours ago

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October 6, 2025

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Credit: @Gf4Tesla/X

A plant manager at a Tesla factory just tipped off the fact that the company will begin production of an affordable model in the coming weeks, all but confirming that a new car will be unveiled tomorrow.

Tesla has been teasing some kind of product unveiling for October 7 on its social media accounts. It has now dropped two separate indications that a new product is coming on its X account.

Fans have been anticipating two things: either the company’s planned affordable model, which has been codenamed “E41,” or the Roadster, a long-awaited vehicle that Tesla has kept under wraps for much longer than it would likely care to admit.

Tesla all but confirms that affordable Model Y is coming Tuesday

André Thierig, Tesla’s plant manager at the German production plant Gigafactory Berlin, tipped off what is likely coming tomorrow at the product unveiling as he revealed during an internal event today that a light version of the Model Y will begin series production and deliveries “in a few weeks.”

Thierig’s revealing of plans was reported by Handelsblatt, a German media outlet.

The description of a “light version of the Model Y” aligns with what CEO Elon Musk said earlier this year, as well as what we have seen on public roads, both covered and uncovered.

Last week, we finally saw an uncovered version of what the affordable model likely is, as it was cruising around near Gigafactory Texas, just outside of Austin.

Tesla coding shows affordable model details, including potential price

Musk said earlier this year, candidly during an Earnings Call, that the affordable model Tesla planned to release was a Model Y.

“It’s just a Model Y. Let the cat out of the bag there,” Musk said.

The images of what we assumed to be the affordable model lined up with Musk’s candid statement:

Tesla is expected to unveil its affordable model tomorrow during the planned event, which has been teased twice. Pricing and other details are still pending, but the company is expected to reveal this information tomorrow.

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Three things Tesla needs to improve with Full Self-Driving v14 release

These are the three things I’d like to see Tesla Full Self-Driving v14 improve.

Published

11 hours ago

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October 6, 2025

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As Tesla plans to release Full Self-Driving version 14 this week after CEO Elon Musk detailed a short delay in its rollout, there are several things that continue to plague what are extremely well-done drives by the suite.

Tesla Full Self-Driving has truly revolutionized the way I travel, and I use it for the majority of my driving. However, it does a few things really poorly, and these issues are consistent across many drives, not just one.

Tesla Full Self-Driving impressions after three weeks of ownership

Musk has called FSD v14 “sentient” and hinted that it would demonstrate drastic improvements from v13. The current version is very good, and it commonly performs some of the more difficult driving tasks well. I have found that it does simple, yet crucial things, somewhat poorly.

These are the three things I’d like to see Tesla Full Self-Driving v14 improve.

Navigation, Routing, and Logical Departure

My biggest complaint is how poorly the navigation system chooses its route of departure. I’ve noticed this specifically from where I Supercharge. The car routinely takes the most illogical route to leave the Supercharger, a path that would require an illegal U-turn to get on the correct route.

I managed to capture this yesterday when leaving the Supercharger to go on a lengthy ride using Full Self-Driving:

You’ll see I overrode the attempt to turn right out of the lot by pushing the turn signal to turn left instead. If you go right, you’ll go around the entire convenience store and end up approaching a traffic light with a “No U-Turn” sign. The car has tried to initiate a U-turn at this light before.

If you’re attempting to get on the highway, you simply have to leave the convenience store on a different route (the one I made the vehicle go in).

It then attempted to enter the right lane when the car needed to remain in the left lane to turn left and access the highway. I manually took over and then reactivated Full Self-Driving when it was in the correct lane.

To achieve Unsupervised Full Self-Driving, such as navigating out of a parking lot and taking the logical route, while also avoiding illegal maneuvers, is incredibly crucial.

Too Much Time in the Left Lane on the Highway

It is illegal to cruise in the left lane on highways in all 50 U.S. states, although certain states enforce it more than others. Colorado, for example, has a law that makes it illegal to drive in the left lane on highways with a speed limit of 65 MPH or greater unless you are passing.

In Florida, it is generally prohibited to use the left lane unless you are passing a slower vehicle.

In Pennsylvania, where I live, cruising in the left lane is illegal on limited-access highways with two or more lanes. Left lanes are designed for passing, while right lanes are intended for cruising.

Full Self-Driving, especially on the “Hurry” drive mode, which drives most realistically, cruises in the left lane, making it in violation of these cruising laws. There are many instances when it has a drastic amount of space between cars in the right lane, and it simply chooses to stay in the left lane:

The clip above is nearly 12 minutes in length without being sped up. In real-time, it had plenty of opportunities to get over and cruise in the left lane. It did not do this until the end of the video.

Tesla should implement a “Preferred Highway Cruising Lane” option for two and three-lane highways, allowing drivers to choose the lane that FSD cruises in.

It also tends to pass vehicles in the slow lane at a speed that is only a mile an hour or two higher than that other car.

This holds up traffic in the left lane; if it is going to overtake a vehicle in the right lane, it needs to do it faster and with more assertiveness. It should not take more than 5-10 seconds to pass a car. Anything longer is disrupting the flow of highway traffic.

Parking

Full Self-Driving does a great job of getting you to your destination, but parking automatically once you’re there has been a pain point.

As I was arriving at my destination, it pulled in directly on top of the line separating two parking spots. It does this frequently when I arrive at my house as well.

Here’s what it looked like yesterday:

Parking is one of the easier tasks Full Self-Driving performs, and Autopark does extremely well when the driver manually chooses the spot. I use Autopark on an almost daily basis.

However, if I do not assist the vehicle in choosing a spot, its performance pulling into spaces is pretty lackluster.

With a lot of hype surrounding v14, Tesla has built up considerable anticipation among owners who want to see FSD perform the easy tasks well. As of now, I believe it does the harder things better than the easy things.

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Elon Musk teases previously unknown Tesla Optimus capability

Elon Musk revealed over the weekend that the humanoid robot should be able to utilize Tesla’s dataset for Full Self-Driving (FSD) to operate cars not manufactured by Tesla.

Published

13 hours ago

on

October 6, 2025

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Credit: @heydave7/X

Elon Musk revealed a new capability that Tesla Optimus should have, and it is one that will surely surprise many people, as it falls outside the CEO’s scope of his several companies.

Tesla Optimus is likely going to be the biggest product the company ever develops, and Musk has even predicted that it could make up about 80 percent of the company’s value in the coming years.

Teasing the potential to eliminate any trivial and monotonous tasks from human life, Optimus surely has its appeal.

However, Musk revealed over the weekend that the humanoid robot should be able to utilize Tesla’s dataset for Full Self-Driving (FSD) to operate cars not manufactured by Tesla:

FSD would essentially translate from operation in Tesla vehicles from a driverless perspective to Optimus, allowing FSD to basically be present in any vehicle ever made. Optimus could be similar to a personal chauffeur, as well as an assistant.

Optimus has significant hype behind it, as Tesla has been meticulously refining its capabilities. Along with Musk’s and other executives’ comments about its potential, it’s clear that there is genuine excitement internally.

This past weekend, the company continued to stoke hype behind Optimus by showing a new video of the humanoid robot learning Kung Fu and training with a teacher:

Tesla plans to launch its Gen 3 version of Optimus in the coming months, and although we saw a new-look robot just last month, thanks to a video from Salesforce CEO and Musk’s friend Marc Benioff, we have been told that this was not a look at the company’s new iteration.

Instead, Gen 3’s true design remains a mystery for the general public, but with the improvements between the first two iterations already displayed, we are sure the newest version will be something special.

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