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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.

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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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Elon Musk just revealed more about Tesla’s June Robotaxi launch

Tesla CEO Elon Musk gave more information about the Robotaxi launch in Austin set for June.

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Steve Jurvetson, CC BY 2.0 , via Wikimedia Commons

Tesla CEO Elon Musk just revealed more details about the company’s June Robotaxi launch, which will kick off in Austin.

As of right now, Tesla is still set to push out the first Robotaxi rides in Austin, Texas, in early June. These vehicles will be in short supply at first, as Musk says the company is purposely rolling out the fleet in a slow and controlled fashion to prioritize safety. There will be ten vehicles in the Robotaxi fleet to start.

Tesla Robotaxi deemed a total failure by media — even though it hasn’t been released

However, in an interview with CNBC on Tuesday afternoon, Musk also revealed some other new details, including where in Austin the vehicles will be able to go, how many Robotaxis we could see on public roads within a few months, and other information regarding Tesla’s Full Self-Driving suite.

A Controlled Rollout

Tesla has maintained for a few months now that the Robotaxi fleet will be comprised of between 10 and 20 Model Y vehicles in Austin.

The Cybercab, which was unveiled by the company last October, will not be available initially, as those cars will likely be produced in 2026.

Musk said during the CNBC interview that Tesla is doing a low-yield trial at first to initiate a safety-first mentality. It is important for Tesla to launch the Robotaxi fleet in a small manner to keep things in check, at least at first.

As confidence builds and the accuracy of the fleet is ensured, more vehicles will be added to the fleet.

Musk believes there will be 1,000 Robotaxis on the road “in a few months.”

Geofenced to Certain Austin Areas

Tesla will be launching the Robotaxi program in a geofenced fashion that gives the company the ability to control where it goes. Musk says that the areas the Robotaxis will be able to travel to are among the safest neighborhoods and areas in Austin.

This is yet another safety protocol that will ensure the initial riders are not put in dangerous neighborhoods.

Some might be disappointed to hear this because of Tesla’s spoken confidence regarding Robotaxi, but the initial rollout does need to be controlled for safety reasons. An accident or incident of any kind that would put riders’ lives in danger would be catastrophic.

No Driver, No Problem

As the company has rolled out an employee-only version of the Robotaxi program in Austin and the San Francisco Bay Area, some wondered whether the rides would be driverless, as these initial trials for Tesla workers were not. Employee rides featured a human in the driver’s seat to ensure safety.

Tesla says it has launched ride-hailing Robotaxi teaser to employees only

The company did not report whether there were any interventions or not, but it did state that the vehicles traveled over 15,000 miles through 1,500 trips.

Musk confirmed during the interview that there will be no driver in the vehicle when the Robotaxi program launches in June. This will be groundbreaking as it will be the first time that Tesla vehicles will operate on public roads without anyone in the driver’s seat.

Full Self-Driving Licensing

For more than a year, Tesla has indicated that it is in talks with another major automaker regarding the licensing of Full Self-Driving. Many speculated that the company was Ford, but neither it nor Tesla confirmed this.

Musk said today that Tesla has been in touch with “a number of automakers” that have inquired about licensing FSD. Tesla has yet to sign any deal to do so.

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Elon Musk on Tesla vehicle sales: “We see no problem with demand”

“The sales numbers at this point are strong, and we see no problem with demand,” Musk said.

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(Credit: Tesla)

During a rather testy interview with Bloomberg’s Mishal Husain at the Qatar Economic Forum, Elon Musk stated that the demand for Tesla’s vehicles is still strong. Musk also stated that the issues that Tesla faced earlier his year have already turned around.

Already Turned Around

Tesla sales saw notable drops in the past months, particularly in Europe, where several countries saw drastically fewer Tesla sales year-over-year. Tesla stated in its Q1 2025 vehicle delivery report that the declines were largely due to the company’s changeover to the new Model Y, but media reports nevertheless placed the blame on Musk’s politics and his work with the Trump administration’s Department of Government Efficiency (DOGE).

It was then no surprise that Bloomberg’s Husain pointed out Tesla’s low sales in Europe this April during the interview. When questioned about the matter, Musk stated that things have “already turned around.” Musk also noted that while Tesla sales are down in Europe so far, this is true for numerous other carmakers in the region.

No Problem With Demand

When asked for evidence to back up his claims, Musk stated that Europe is indeed Tesla’s weakest market, but the company remains “strong everywhere else.” He also admitted that while Tesla has “lost some sales from the left,” the company also “gained some from the right.” Musk highlighted the fact that Tesla stock, which is partly affected by analysts with insider information, is trading at near all-time highs.

“The sales numbers at this point are strong, and we see no problem with demand. You can just look at the stock price. If you want the best insider information, the stock market analysts have that, and our stock wouldn’t be trading near all-time highs if things weren’t in good shape. They’re fine. Don’t worry about it,” Musk said. 

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Watch Elon Musk’s full interview at the Qatar Economic Forum in the video below.

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Tesla’s Elon Musk confirms he’ll stay CEO for at least five more years

Tesla CEO Elon Musk eased any speculation about his role with the company as he confirmed he would be with the automaker for at least five more years.

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Tesla CEO Elon Musk unveils futuristic Cybertruck in Los Angeles, Nov. 21, 2019 (Photo: Teslarati)

Tesla’s Elon Musk said that he will still be CEO of the automaker in five years’ time, dispelling any potential skepticism regarding his commitment or plans with the company.

In the past, there was some speculation that Musk would leave Tesla if he was not adequately compensated for his work. He had a massive pay package taken from him by Delaware Judge Kathaleen McCormick in a move that caused Tesla to reincorporate its company in Texas.

Tesla Chair of the Board letter urges stockholders to approve Texas reincorporation

However, Musk confirmed today with a simple “Yes” that he would still be Tesla’s frontman in five years during an interview with Bloomberg at the Qatar Economic Forum:

“Do you see yourself and are you committed to still being the chief executive of Tesla in five years’ time?”

“Yes.”

Musk has had the massive $56 billion pay package declined twice by Chancellor McCormick, who has ruled that the pay was an “unfathomable sum.” Shareholders have voted twice in overwhelming fashion to award Musk with the pay package, but she has overruled it twice. This seemed to be one reason Musk might minimize his role or even step away from Tesla.

He said (via Bloomberg):

“The compensation should match that something incredible was done. But I’m confident that whatever some activist posing as a judge in Delaware happens to do will not affect the future compensation.”

Musk’s commitment to Tesla for the next five years will help steer the company in a more stable direction as it begins to expand its market well past automotive and sustainable energy. Although Tesla has been labeled as an AI company, it is also starting to push more into the robotics industry with the future release of the Optimus robot.

Now that Musk is on board for at least five more years, Tesla investors have their frontman, who has remained firm on the company’s vision to be a true disruptor in all things tech. The company’s stock is trading up just over 1 percent at the time of publication.

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