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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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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.

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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Elon Musk

Tesla Roadster owners to get “Flying Stunt Mode” and looping track access

Musk says Roadster owners can command the unveiling stunts autonomously, with a Texas looping track.

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Elon Musk says owners of the new Tesla Roadster will be able to ask the car to perform the stunts Tesla showed at its unveiling, with the car doing the driving itself. Musk made the comment Saturday in a reply on X to tech blogger Robert Scoble, and he added a promise of a looping track at Tesla’s Texas headquarters.

Scoble had argued that the person in the Roadster is not really driving it. In his description, the driver operates a computer that tells another computer what to do, with steering, braking and acceleration all handled by wire. Musk answered, “True. You will be able to ask the Roadster to perform any of the tricks shown autonomously, as it will be sentient. Also, we will have a wild looping track (crazier even than Hot Wheels) at our Texas HQ where you can test out your Roadster.”

At the October 15 event outside Waco, the car drove up a curved ramp until it was upside down, flew off on cold gas thrusters, flipped and landed. It also hovered over a Cybercab, Cybertruck, Semi, Model Y and Model 3 while moving. As we noted in our breakdown of the three Roadster configurations, Musk said at the event that the car “literally is just going to puff itself up” to perform the maneuvers whenever an owner wants. Saturday’s reply adds that the car would run them on its own.

Tesla has described some of the hardware that would make that possible. The Roadster uses steer by wire with a yoke, and its cold gas thrusters rely on electric actuators for small adjustments in flight. A fan system under the car creates suction, which Tesla says is strong enough to hold it upside down, a setup we covered in our look at the Roadster’s fan system and thrusters.

Musk did not say when an autonomous stunt feature might arrive, how it would work, or what he means by sentient. He also gave no size, location or opening date for the Texas track. Production is planned for Giga Texas in 2027 or 2028, and Tesla says the car is not approved for public road use. The Rocket version, the one built to fly, is invite only.

The comment follows a week of Musk teasing the event, including his claim that the demo would be a banger, which we covered before the stream. Tesla reports third quarter earnings on October 21, and shareholders can submit and vote on questions through the Say portal until 4 p.m. EDT on October 20, according to our earnings Q&A preview. A question about autonomous Roadster stunts and the Texas track would be a quick way to get specifics from management.

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Elon Musk

How to use Grok Bot to block spam calls and texts

Musk told users to ask Grok Bot to scrub their phone numbers from spam lists.

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Elon Musk has a new use case for Grok Bot, and it is the spam call. On Thursday he replied to an X user named Arash with a short instruction: “Ask your @Grok @Bot to remove your phone number from spam call & text lists!” Arash had said he got tired of the calls, had an AI bot find his number on listing sites and file removal requests, and packaged the process as a free skill for others.

The skill is called Spam-Call Scrubber, which is described to find a phone number on people search sites and data brokers, submits the opt outs, completes the confirmation emails those sites send back, and rechecks on a schedule the user picks. Using it requires the Grok Bot app. The pitch is time saved, since most broker opt outs sit behind separate forms on separate sites.



Musk said Grok Bot now gives each bot its own email address, and that it can detect scam emails. On Thursday he also said SpaceX would make users whole if the bot botches a purchase or leaks a card, then told users to shop away from Amazon after the retailer blocked the agent, as Teslarati reported. The terms of service we reviewed at the time put responsibility for what an agent does on the user.

For Tesla owners, Grok Bot is not just a phone app. Tesla brought Grok Bot into its vehicles on September 22, and we argued earlier this week that the Cybercab’s real advantage may be the errands it runs during a ride. Every Cybercab and the rest of the Model Y Robotaxi fleet has it enabled. The more routine tasks like this one become, the more a rider has reason to hand over something personal in the back seat.

The new Spam-Call Scrubber skill can be downloaded for free and works on sites that honor removal requests, while noting that listings can reappear, and illegal robocallers do not check any registry. Whether Spam-Call Scrubber cuts anyone’s call volume is something the first wave of users will find out, and Musk’s endorsement guarantees that wave is coming.

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Investor's Corner

Tesla’s flying Roadster just revealed something bigger than the car

Analysts say the Roadster demo puts a Tesla and SpaceX merger back on the table.

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Tesla’s new Roadster, upside down and trailing cold gas thruster smoke, flips over a lineup of Tesla vehicles at the Roadster unveiling near Waco, Texas on October 15, 2026. (Image: Tesla)
Tesla’s new Roadster, upside down and trailing cold gas thruster smoke, flips over a lineup of Tesla vehicles at the Roadster unveiling near Waco, Texas on October 15, 2026. (Image: Tesla)

The Roadster unveiling near Waco ended Thursday night, and by Friday morning much of the investor reaction had less to do with the car than with who owns the rocket technology inside it.

Wedbush analyst Dan Ives said the event “puts the Tesla/SpaceX relationship on the table in a tangible way,” pointing to the propulsion, pressure vessel and control hardware sitting on a Tesla product. Gene Munster of Deepwater Asset Management called the demo “a ridiculous display of engineering” with “no commercial value” beyond embarrassing traditional automakers, though he said it showed Musk wants the two companies together.

The more specific forecast came a day earlier from Barclays. Analyst Dan Levy told clients a deal could be announced before Tesla’s annual meeting, which must happen by December 6, and that an announcement in late October or early November could make shareholder approval harder. Barclays expects SpaceX to be the buyer in an all stock deal, with Tesla holders receiving SpaceX shares at a premium, based on market values of roughly $2.1 trillion for SpaceX and $1.5 trillion for Tesla. If nothing lands around the meeting, the bank still sees an announcement within 6 to 12 months.

The Roadster demo just added more weight to merger speculations. Tesla’s demo used cold gas thrusters and pressure tanks of the kind SpaceX uses on Falcon 9, and Musk described the car as a collaboration between Tesla and SpaceX engineers, as we mentioned in our breakdown of the three Roadster configurations.


Musk has not publicly addressed a deal since the event, as far as we have seen. His most direct answer remains the one he gave at the All In Summit, when he said that with so much collaboration, “who can imagine what action one might take” without ruling anything out. Ives has held to a 2027 timeline since his March note, and Musk pushed back on the China piece of the speculation when ARK floated a year end announcement in August.

The next test is Tesla’s third quarter earnings call on October 21. However, we recall in July that Musk told analysts, “we can’t talk about combining companies and that kind of thing on an earnings call,” so a clear answer wouldn’t be expected.

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