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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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Tesla to launch in India in July with vehicles already arriving: report

Tesla is finally making serious moves toward launching in India, with showrooms opening in July, a report claims.

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Credit: Tesla

Tesla is finally bringing its business to India, a new report indicates, as the company is already shipping vehicles from China to the market where it has attempted to launch business for several years.

We first heard of Tesla planning to launch in India about a decade ago when CEO Elon Musk and Indian Prime Minister Narendra Modi met in California at the Fremont Factory in 2015.

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Over the years, the two have hinted that the automaker would eventually land in India, but issues with import duties have delayed Tesla’s attempts.

Now, there seems to be some serious movement in Tesla’s plans, as it has reportedly shipped the first batch of vehicles from China to India, according to Bloomberg. The outlet says these are Model Y Rear-Wheel-Drive configurations.

Tesla is also planning for other parts of the launch, like preparing for Supercharging, aftermarket parts and merchandise purchasing for vehicle owners and fans, and spare parts from various regions, including the United States, China, and the Netherlands.

The company and the Indian government must have come to some sort of agreement that was catalyzed by Musk and Modi’s meeting in February in the U.S.

It is a long time coming, and it now gives Tesla access to an incredibly vast market in India, where a very small percentage of 2024’s total automotive sales were comprised of electric vehicles.

Another interesting tidbit about the launch is that the vehicles will be coming from Gigafactory Shanghai and not Gigafactory Berlin as previously thought. Reports from other publications, like Reuters, indicated the German production facility was building vehicles for India early last year.

India has a very strict policy that favors domestic manufacturing, which is why the import duties were so high for foreign automakers looking to bring their product into the market. These duties were reduced from 110 percent to just 15 percent, as long as companies aim to invest in India and meet certain investment and sales targets.

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SpaceX and Elon Musk share insights on Starship Ship 36’s RUD

Starship Ship 36 experienced a Rapid Unscheduled Disassembly during a static fire attempt.

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Elon Musk and SpaceX provided an explanation for the Rapid Unscheduled Disassembly (RUD) of Starship Ship 36 on Wednesday. As per Musk, preliminary data suggests that a nitrogen composite overwrapped pressure vessel (COPV) in the vehicle’s payload bay failed below its proof pressure.

On Wednesday evening, Ship 36 experienced a RUD during a static fire attempt. Videos of the incident that were shared online showed Starship Ship 36 exploding into a massive fireball at its launchpad in Starbase, Texas. Images taken in the aftermath of the explosion showed significant damage to the plumbing in the area. The site’s pad structure was also destroyed.

Elon Musk shared some information immediately after the incident. In a response to a post from space enthusiast @Erdayastronaut, Musk stated that “Preliminary data suggests that a nitrogen COPV in the payload bay failed below its proof pressure.”

Musk also noted that, “If further investigation confirms that this is what happened, it is the first time ever for this design.”

SpaceX provided more insight into the incident in a post on its official website.

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“After completing a single-engine static fire earlier this week, the vehicle was in the process of loading cryogenic propellant for a six-engine static fire when a sudden energetic event resulted in the complete loss of Starship and damage to the immediate area surrounding the stand.

“The explosion ignited several fires at the test site, which remains clear of personnel and will be assessed once it has been determined to be safe to approach. Individuals should not attempt to approach the area while safing operations continue,” SpaceX wrote in its post.

SpaceX highlighted that despite Starship Ship 36’s RUD, the incident will not result in any hazards to the surrounding communities in the Rio Grande Valley. And in a post on X, SpaceX also confirmed that everyone in the Starship team was safe and accounted for after Ship 36’s explosion.

While Ship 36’s RUD is a speed bump for the Starship program, SpaceX is a company that is known to grow stronger with every adversity. Thus, it would not be surprising if SpaceX implemented numerous improvements to Starship after this incident–improvements that would make the vehicle more reliable and safer than before.

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Tesla has started rolling out initial round of Robotaxi invites

Tesla is putting safety above all in its initial Robotaxi rollout.

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Credit: @BLKMDL3/X

Tesla has started rolling out an initial round of invites for its upcoming Robotaxi service in Austin, Texas.

Screenshots shared by several Tesla community members who received the invites provided a quick overview of the autonomous ride-hailing service.

As noted in a techAU report, the initial round of Robotaxi service invites has gone to longtime Tesla owners and active members of the EV community. These include owners such as @SawyerMerritt, @BLKMDL3, @WholeMarsBlog, @ItsKimJava, and @HerbertOng, all of whom shared screenshots of the invitation that Tesla has sent about the upcoming service.

You’re Invited to Early Access of Tesla Robotaxi!

The Future is Now! You’re invited to Early Access of Tesla’s Robotaxi service in Austin, TX!

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As an Early Access rider, you can be among the first to use our new Robotaxi App and experience an autonomous ride within our geofenced area in Austin. Through this exclusive preview, you’ll have the opportunity to provide valuable feedback on our Robotaxi service.

Based on Tesla’s message, it appears that participation in the service would be strictly invite-only for now. Participants must also download Tesla’s dedicated Robotaxi App to hail a ride. Rides can also be requested and initiated to and from any location within a geofenced area of Austin.

The robotaxi service will be available from 6:00 AM to 12:00 AM, seven days a week, though these hours may change depending on factors such as inclement weather. Interestingly enough, Tesla is inviting the first participants of the Robotaxi program to share photos and videos of their experience with the service.

While the vehicles themselves are autonomous and would operate without human input, the Robotaxis would still be accompanied by a Tesla staff member to monitor the vehicle. This strategy suggests that Tesla is really putting safety above all in its initial Robotaxi rollout.

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