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SpaceX installs orbital Starship heat shield prototype with robots

SpaceX has begun testing methods of installing Starship's massive heat shield in South Texas. (NASASpaceflight - bocachicagal)

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5 years ago

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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.

SpaceX tested hexagonal Starship heat shield tiles on Starhopper’s second and final hop test. (NASASpaceflight – bocachicagal)
Starship SN4, April 2020. (NASASpaceflight – bocachicagal)
Starship SN5, August 2020. (NASASpaceflight – bocachicagal)
SpaceX tested a few Starship heat shield tiles in 2019 on Cargo Dragon’s orbital CRS-18 mission. (SpaceX)

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.

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The first sign of broader-scale heat shield installation test was spotted on July 9th by local resident Andrew Goetsch, aka Nomadd. (NASASpaceflight – Nomadd)

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.

SpaceX accepted delivery of several manufacturing robots on July 21. (NASASpaceflight – bocachicagal)
Inconspicuously labeled “HEAT SHIELD”, one of those robots was spotted two weeks later. (NASASpaceflight – bocachicagal)

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”.

Another five days later, photos of the first large-scale heat shield installation test were captured for the first time. (NASASpaceflight – bocachicagal)
August 10th. (NASASpaceflight – bocachicagal)

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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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 Supercharger Diner food menu gets a sneak peek as construction closes out

What are you ordering at the Tesla Diner?

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9 hours ago

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July 18, 2025

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Credit: BradGoldbergMD | X

The Tesla Supercharger Diner in Los Angeles is nearing completion as construction appears to be winding down significantly. However, the more minor details, such as what the company will serve at its 50s-style diner for food, are starting to be revealed.

Tesla’s Supercharger Diner is set to open soon, seven years after CEO Elon Musk first drafted the idea in a post on X in 2018. Musk has largely come through on most of what he envisioned for the project: the diner, the massive movie screens, and the intended vibe are all present, thanks to the aerial and ground footage shared on social media.

We already know the Diner will be open 24/7, based on decals placed on the front door of the restaurant that were shared earlier this week. We assume that Tesla Optimus will come into play for these long and uninterrupted hours.

The Tesla Diner is basically finished—here’s what it looks like

As far as the food, Tesla does have an email also printed on the front door of the Diner, but we did not receive any response back (yet) about what cuisine it will be offering. We figured it would be nothing fancy and it would be typical diner staples: burgers, fries, wings, milkshakes, etc.

According to pictures taken by @Tesla_lighting_, which were shared by Not a Tesla App, the food will be just that: quick and affordable meals that diners do well. It’s nothing crazy, just typical staples you’d find at any diner, just with a Tesla twist:

As the food menu is finalized, we will be sure to share any details Tesla provides, including a full list of what will be served and its prices.

Additionally, the entire property appears to be nearing its final construction stages, and it seems it may even be nearing completion. The movie screens are already up and showing videos of things like SpaceX launches.

There are many cars already using the Superchargers at the restaurant, and employees inside the facility look to be putting the finishing touches on the interior.

It’s almost reminiscent of a Tesla version of a Buc-ee’s, a southern staple convenience store that offers much more than a traditional gas station. Of course, Tesla’s version is futuristic and more catered to the company’s image, but the idea is the same.

It’s a one-stop shop for anything you’d need to recharge as a Tesla owner. Los Angeles building permits have not yet revealed the date for the restaurant’s initial operation, but Tesla may have its eye on a target date that will likely be announced during next week’s Earnings Call.

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News

Tesla’s longer Model Y did not scale back requests for this vehicle type from fans

Tesla fans are happy with the new Model Y, but they’re still vocal about the need for something else.

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1 day ago

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July 17, 2025

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Credit: AlwinArt/Twitter

Tesla launched a slightly longer version of the Model Y all-electric crossover in China, and with it being extremely likely that the vehicle will make its way to other markets, including the United States, fans are still looking for something more.

The new Model Y L in China boasts a slightly larger wheelbase than its original version, giving slightly more interior room with a sixth seat, thanks to a third row.

Tesla exec hints at useful and potentially killer Model Y L feature

Tesla has said throughout the past year that it would focus on developing its affordable, compact models, which were set to begin production in the first half of the year. The company has not indicated whether it met that timeline or not, but many are hoping to see unveilings of those designs potentially during the Q3 earnings call.

However, the modifications to the Model Y, which have not yet been officially announced for any markets outside of China, still don’t seem to be what owners and fans are looking forward to. Instead, they are hoping for something larger.

A few months ago, I reported on the overall consensus within the Tesla community that the company needs a full-size SUV, minivan, or even a cargo van that would be ideal for camping or business use.

Tesla is missing one type of vehicle in its lineup and fans want it fast

That mentality still seems very present amongst fans and owners, who state that a full-size SUV with enough seating for a larger family, more capability in terms of cargo space for camping or business operation, and something to compete with gas cars like the Chevrolet Tahoe, Ford Expedition, or electric ones like the Volkswagen ID.BUZZ.

We asked the question on X, and Tesla fans were nearly unanimously in support of a larger SUV or minivan-type vehicle for the company’s lineup:

Here’s what some of the respondents said:

Tesla is certainly aware that many of its owners would like the company to develop something larger that competes with the large SUVs on the market.

However, it has not stated that anything like that is in the current plans for future vehicles, as it has made a concerted effort to develop Robotaxi alongside the affordable, compact models that it claims are in development.

It has already unveiled the Robovan, a people-mover that can seat up to 20 passengers in a lounge-like interior.

The Robovan will be completely driverless, so it’s unlikely we will see it before the release of a fully autonomous Full Self-Driving suite from Tesla.

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Energy

Tesla launches first Virtual Power Plant in UK – get paid to use solar

Tesla has launched its first-ever Virtual Power Plant program in the United Kingdom.

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1 day ago

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July 17, 2025

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Credit: Tesla Energy | X

Tesla has launched its first-ever Virtual Power Plant program in the United Kingdom. This feature enables users of solar panels and energy storage systems to sell their excess energy back to the grid.

Tesla is utilizing Octopus Energy, a British renewable energy company that operates in multiple markets, including the UK, France, Germany, Italy, Spain, Australia, Japan, New Zealand, and the United States, as the provider for the VPP launch in the region.

The company states that those who enroll in the program can earn up to £300 per month.

Tesla has operated several VPP programs worldwide, most notably in California, Texas, Connecticut, and the U.S. territory of Puerto Rico. This is not the first time Tesla has operated a VPP outside the United States, as there are programs in Australia, Japan, and New Zealand.

This is its first in the UK:

Tesla is not the only company that is working with Octopus Energy in the UK for the VPP, as it joins SolarEdge, GivEnergy, and Enphase as other companies that utilize the Octopus platform for their project operations.

It has been six years since Tesla launched its first VPP, as it started its first in Australia back in 2019. In 2024, Tesla paid out over $10 million to those participating in the program.

Tesla VPP program in California hits new capacity milestone

Participating in the VPP program that Tesla offers not only provides enrolled individuals with the opportunity to earn money, but it also contributes to grid stabilization by supporting local energy grids.

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