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SpaceX installs orbital Starship heat shield prototype with robots
SpaceX has begun large-scale Starship heat shield installation tests with the help of robots delivered last month in a sign that the company has already begun preparing for the rocket’s first orbital flight test campaign.
Designed to eventually replace SpaceX’s workhorse Falcon 9 and Falcon Heavy launch vehicles, Starship is a fully-reusable two-stage rocket powered by methane and oxygen-fueled Raptor engines. Just like Falcon 9, Starship’s first stage (known as Super Heavy) will launch the combined spacecraft and upper stage to an altitude of 70 to 100 km (40-65 mi) and velocity of ~2.5 to 3 kilometers per second (1.5-1.9 mi/s). Super Heavy will separate, boost back towards land, and either land back at the launch pad or on a floating platform.
SpaceX already has extensive experience launching, landing, and reusing orbital-class rocket boosters thanks to Falcon 9 and Heavy, which have completed 57 landings and been reused 39 times in less than five years. The Starship upper stage, however, will have to survive orbital-velocity atmospheric reentries some 3 to 5 times faster and exponentially more energetic than Super Heavy boosters. To do so routinely while keeping Starship cost and complexity low and reusability high, SpaceX will have to develop an unprecedentedly effective heat shield that is easier to install, maintain, and reuse than anything that has come before it.
As with all SpaceX programs, the company began Starship heat shield installation development as soon as possible, installing a handful of tiles (presumably early-stage prototypes) on Starhopper as far back as H1 2019. This continued with small hexagonal tile installation tests on Starships SN1, SN3, SN4, SN5, and SN6 throughout 2020. While those coupon tests obviously didn’t involve orbital-class reentry heating or buffeting, they were still useful to characterize the mechanical behavior of heat shield tiles under the stress of cryogenic propellant loading, Raptor static fires, and hop tests.
In 2019, SpaceX even tested a few ceramic Starship heat shield tiles on an orbital Cargo Dragon mission for NASA. The fact that no more orbital Cargo or Crew Dragon tests were acknowledged seems to suggest that the demonstration was a success, proving that the tiles can stand up to the stresses of reentry from low Earth orbit (LEO).
Behind the scenes, SpaceX is assuredly performing extensive laboratory-style tests with tiles and an agreement signed with NASA Ames Research Center confirmed that the company is using the facility’s arcjet to physically simulate the conditions of orbital-velocity reentry. Tests on the scale of a full Starship, however, are an entirely different story.
The first signs of large-scale heat shield installation testing appeared on July 9th when local resident and photographer Andrew Goetsch (Nomadd) captured photos of a test coupon covering half of an entire steel Starship ring. In April 2020, CEO Elon Musk confirmed on Twitter that the current design involved affixed heat shield tiles directly to Starship’s steel hull with steel studs. It’s unclear how exactly the company is installing steel studs directly onto the ~4mm (0.15 in) thick skins of a pressure vessel or if an off -the-shelf solution was available but Nomadd’s July 9th photos explicitly show the process required to refine the settings on the mystery stud installer.
One month after Nomadd’s spotting, three weeks after a robot delivery, and five days after one of those robots – labeled “HEAT SHIELD – was spotted in action, the first large-scale heat shield installation test article was spotted inside one of SpaceX’s several production tents. The team involved clearly had some fun with the process, installing the tiles in the form of a SpaceX “X”.
In retrospect, robots could be a perfect solution for the affordable, high-volume installation of the thousands of heat shield tiles a single Starship will need. Once tolerances are high enough, it’s conceivable that multiple different Starship sections could be individually outfitted with studs and heat shield tiles by robot, inspected by humans, and joined together to form a complete Starship. Humans would likely need to manually install a gap of tiles around the weld lines of those final sections, but the manual installation work would be reduced to a minimum while keeping the required infrastructure dead simple.
Ultimately, a great deal of work remains before SpaceX can even begin to feasibly attempt orbital Starship test flights, but it’s hard not to get excited by the fact that some of that preparatory work has already visibly begun in South Texas.
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Tesla plans to resolve its angriest bunch of owners: here’s how
Since the rollout of the AI4 chip in Tesla vehicles, owners with the last generation self-driving chip, known as Hardware 3, have been persistent in their quest for a solution to their issue: they were told their cars were capable of unsupervised Full Self-Driving. It turns out the cars are not.
Tesla has a plan to make Hardware 3 owners whole after CEO Elon Musk admitted that those with that self-driving chip in their cars will not have access to unsupervised Full Self-Driving.
The company’s strategy is so crazy that it is sort of hard to believe.
Since the rollout of the AI4 chip in Tesla vehicles, owners with the last generation self-driving chip, known as Hardware 3, have been persistent in their quest for a solution to their issue: they were told their cars were capable of unsupervised Full Self-Driving. It turns out the cars are not.
Tesla owners with HW3 finally get their answer: https://t.co/CSZTKKkWXx
— TESLARATI (@Teslarati) April 22, 2026
During the Tesla Q1 earnings call on Wednesday, Musk finally clarified what the company’s plans are for Hardware 3 owners, what they will be offered, and what Tesla will have to do internally to prepare for it.
The answer was somewhat mind-boggling.
Musk said:
“Unfortunately, Hardware 3 — I wish it were otherwise, but Hardware 3 simply does not have the capability to achieve unsupervised FSD. We did think at one point it would have that, but relative to Hardware 4, it has only 1/8 of the memory bandwidth of Hardware 4. And memory bandwidth is one of the key elements needed for unsupervised FSD.”
He continued, stating that HW3 owners would have the opportunity to trade their cars in at a discounted rate in order to get the AI4 chip:
“So for customers that have bought FSD, what we’re offering is essentially a trade-in — like a discounted trade-in for cars that have AI4 hardware, and we’ll also be offering the ability to upgrade the car, to replace the computer. And you also need to replace the cameras, unfortunately, to go to Hardware 4.”
Obviously, Tesla has a lot of people to work with and make this whole thing right. Musk was adamant that HW3 would be capable of FSD, and now that the company has finally admitted that it is not, there are some things that could come of this.
There has been open talk about some sort of class action lawsuit against Tesla. The promises that Tesla made previously could be considered a breach of contract or even false advertising, and that’s according to Grok, Musk’s own AI program.
Musk went on to say that Tesla would likely have to establish new microfactories to effectively and efficiently replace HW3 computers and cameras:
…So to do this efficiently, we’re going to have to set up, like kind of micro factories or small factories in major metropolitan areas in order to do it efficiently. Because if it’s done just at the service center, it is extremely slow to do so and inefficient. So we basically need like many production lines to make the change.”
This is going to be an extremely costly process, especially if Tesla has to buy real estate, properties, and equipment to complete this work. Additionally, there was no wording on pricing, but Musk never said it would be free. It will likely come with some kind of price tag, and HW3 owners, after being left hanging for so long, will have something to say about that.
Elon Musk
SpaceX just got pulled into the biggest Weapons Program in U.S. history
SpaceX joins the Golden Dome software group, deepening its role in America’s most expensive defense program.
SpaceX has joined a nine-company group developing the core operating software for the Golden Dome, America’s next-generation missile defense system. According to a Bloomberg report, SpaceX is focused on integrating satellite communications for military operations and is working alongside eight other defense and artificial intelligence companies, including Anduril Industries, Palantir Technologies, and Aalyria Technologies, to build software connecting missile defense capabilities.
The Golden Dome concept dates back to President Trump’s 2024 campaign, and on January 27, 2025, he signed an executive order directing the U.S. Armed Forces to construct the system before the end of his term. The system is planned to employ a constellation of thousands of satellites equipped with interceptors, with data centers in space providing automated control through an AI network.
FCC accepts SpaceX filing for 1 million orbital data center plan
Space Force Gen. Michael Guetlein, director of the Golden Dome initiative, has described the software layer as a “glue layer” that would enable officers to manage and control radars, sensors, and missile batteries across services. The consortium is aiming to test the platform this summer.
Trump selected a design in May 2025 with a $175 billion price tag, expected to be operational by the end of his term in 2029, though the Congressional Budget Office projected the cost could reach $831 billion over two decades.
The Golden Dome role is only the latest in a string of military wins for SpaceX. As Teslarati reported, the U.S. Space Force awarded SpaceX a $178.5 million task order on April 1, 2026 to launch missile tracking satellites for the Space Development Agency, covering two Falcon 9 launches beginning in Q3 2027. That came on top of more than $22 billion in government contracts held by SpaceX as of 2024, per CEO Gwynne Shotwell, spanning NASA resupply missions, classified intelligence satellites through its Starshield program, and military broadband.
The accumulation of defense contracts, now including a seat at the table on the most expensive weapons program in U.S. history, positions SpaceX as the dominant infrastructure provider for American national security in space. With a SpaceX IPO still on the horizon, each new contract adds weight to what is already one of the most consequential companies in aerospace history, raising real questions about how much of America’s defense architecture will depend on a single private operator before it ever trades publicly.
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Tesla pulls back the curtain on Cybercab mass production
Tesla’s Cybercab drives itself off the Gigafactory Texas line in a striking new production video.
Tesla has provided a first look from inside a production Cybercab as it drove itself off the assembly line at Gigafactory Texas. The video footage, posted on X, opens on the factory floor with robotic arms and assembly equipment visible through the Cybercab windshield, and follows the car through a branded tunnel marked “Cybercab”, before autonomously navigating itself to a holding lot.
The first Cybercab rolled off the Giga Texas production line on February 17, 2026, with Musk writing on X, “Congratulations to the Tesla team on making the first production Cybercab.” April marked the official shift to volume production. The Giga Texas line is being prepared to produce hundreds of units per week, with 60 units already spotted on the Gigafactory campus earlier this month.
Purpose-built for autonomy
Cybercab in production now at Giga Texas pic.twitter.com/Y9qG3KyWBa
— Tesla (@Tesla) April 23, 2026
The Cybercab was first revealed publicly at Tesla’s “We, Robot” event in October 2024 at Warner Bros. Studios in Burbank, California, where 20 pre-production units gave attendees rides around the studio lot. Musk said he believed the average operating cost would be around $0.20 per mile, and that buyers would be able to purchase one for under $30,000. The two-seat design is deliberate. Musk noted that 90 percent of miles driven involve one or two people, making a compact two-passenger vehicle the most efficient configuration for a fleet-scale robotaxi. Eliminating rear seats also removes complexity and cost, supporting that sub-$30,000 target.
Tesla’s annual production goal is 2 million Cybercabs per year once several factories reach full design capacity. The Cybercab has no steering wheel, no pedals, and relies entirely on Tesla’s vision-based FSD system. What the video shows is the first evidence of that system working not as a demo, but as a production reality, driving itself off the line and into the world.
🚗 Our first ride in Tesla Cybercab last October: pic.twitter.com/kGqIqgJPRn https://t.co/BITCXFhbVd
— TESLARATI (@Teslarati) April 22, 2025
Tesla plans to resolve its angriest bunch of owners: here’s how
SpaceX just got pulled into the biggest Weapons Program in U.S. history
