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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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6 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.

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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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Tesla Cybercab gets crazy change as mass production begins

Tesla has officially kicked off mass production of its groundbreaking Cybercab robotaxi at Giga Texas, and the first units rolling off the line feature a striking transformation that’s turning heads across the EV community.

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1 hour ago

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April 25, 2026

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Credit: TechOperator | X

Tesla Cybercab has evidently received a pretty crazy change from an aesthetic standpoint, as the company has made the decision to offer an additional finish on the vehicle as mass production is starting.

Tesla has officially kicked off mass production of its groundbreaking Cybercab robotaxi at Giga Texas, and the first units rolling off the line feature a striking transformation that’s turning heads across the EV community.

VIN Zero—the very first production Cybercab—showcases a vibrant champagne gold exterior with a high-gloss finish, a dramatic departure from the flat, matte-wrapped prototypes that debuted at the 2024 “We, Robot” event.

This glossy sheen is a pretty big pivot from what was initially shown by Tesla. The company has maintained a pretty flat tone in terms of anything related to custom colors or finishes.

A specialized clear coat or process delivers the deep, reflective gloss without conventional painting. The result is a premium, mirror-like shine, and it looks pretty good, and gives the compact two-seater a more luxurious and futuristic presence than the subdued matte prototypes.

Photos shared by Tesla community members reveal VIN Zero in a showroom-like setting at Giga Texas, highlighting refined panel gaps, large aero wheel covers, and the signature no-steering-wheel, no-pedals interior optimized for full autonomy.

The open frunk in some images offers a glimpse of practical storage, while the overall build quality appears more polished than that of test mules.

This glossy evolution aligns with Tesla’s broader production ramp. After the first unit in February 2026, the company has shifted to volume manufacturing, with dozens of units already spotted in outbound lots. CEO Elon Musk and the team aim for hundreds per week, paving the way for unsupervised FSD robotaxi networks that could slash ride costs to pennies per mile.

The Cybercab holds Tesla’s grand ambitions of operating a full-service ride-hailing service without any drivers in its grasp. Tesla has yet to solve autonomy, but is well on its way, and although its timelines are usually a bit off, improvements often come through the Over-the-Air updates to the Full Self-Driving suite.

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Tesla confirms Cybercab with no steering wheel enters production

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5 hours ago

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April 25, 2026

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Tesla has confirmed today that its steering wheel-less and pedal-less Cybercab, the vehicle geared toward launching the company’s autonomous ride-hailing hopes, has officially entered production at its Giga Texas production facility outside of Austin.

The Cybercab is a sleek two-door, two-passenger coupe engineered from the ground up as an electric self-driving vehicle. It features no steering wheel or pedals, relying instead on Tesla’s advanced vision-only Full Self-Driving system powered by multiple cameras and artificial intelligence.

The minimalist cabin centers on a large display screen that serves as the primary interface for passengers, creating an open, futuristic space optimized for comfort during unsupervised rides. A compact 35-kilowatt-hour battery pack delivers exceptional efficiency at 5.5 miles per kilowatt-hour, providing an estimated 200-mile range.

Additional innovations include inductive charging compatibility and a lightweight design that enhances aerodynamics and performance.

Production at Giga Texas builds on earlier prototypes and initial units completed earlier in 2026. The facility, already a hub for Model Y and Cybertruck assembly, now ramps up dedicated lines for the Cybercab.

This shift to volume manufacturing reflects Tesla’s strategy to scale affordable autonomous vehicles rapidly.

By focusing on a dedicated platform rather than adapting existing models, the company aims to keep costs low while prioritizing safety and reliability through continuous AI improvements.

The Cybercab’s debut in production carries broad implications for urban mobility. As the cornerstone of Tesla’s Robotaxi network, it promises on-demand, driverless rides that could slash transportation expenses, reduce traffic accidents caused by human error, and lower emissions through its all-electric powertrain.

Accessibility features, such as space for service animals or assistive devices, further broaden its appeal. Regulators and cities worldwide will soon evaluate its deployment, but the vehicle’s design already addresses key hurdles in scaling unsupervised autonomy.

Challenges persist, including full regulatory clearance and building charging infrastructure. Yet this production launch signals momentum. With Cybercabs poised to roll out in increasing numbers, Tesla edges closer to a future where personal ownership meets shared fleets of intelligent vehicles.

The start of Cybercab production is more than just a new vehicle entering mass manufacturing for Tesla, as it’s a signal autonomy is near. Being developed without manual controls is such a massive sign by Tesla that it trusts its progress on Full Self-Driving.

While the development of that suite continues, Tesla is making a clear cut statement that it is prepared to get its fully autonomous vehicle out in public roads as it prepares to revolutionize passenger travel once and for all.

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Tesla Summon got insanely good in FSD v14.3.2 — Navigation? Not so much

There were two new lines of improvements in the release notes: one addressing Actually Smart Summon (ASS), and another that now allows drivers to choose a reason for an intervention via a small menu during disengagement.

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1 day ago

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April 24, 2026

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(Photo: Hector Perez/YouTube)

Tesla Full Self-Driving v14.3.2 began rolling out to some owners earlier this week, and there are some notable improvements that came with this update.

There were two new lines of improvements in the release notes: one addressing Actually Smart Summon (ASS), and another that now allows drivers to choose a reason for an intervention via a small menu during disengagement.

Overall operation saw a handful of slight improvements, especially with parking performance, which has been the most notable difference with the arrival of FSD v14.3. However, there are still some very notable shortcomings, most notably with region-specific signage and navigation.

Tesla Assisted Smart Summon (ASS) improvements

There are noticeable improvements to ASS operation, which has definitely been inconsistent in terms of performance. Tesla wrote in the release notes for v14.3.2:

“Unified the model between Actually Smart Summon, FSD, and Robotaxi for more capable and reliable behavior.”
As recently as this month, I used Summon with no success. It had pulled around the parking lot I was in incorrectly, leaving the range at which Summon can be operated and losing a signal while moving in the middle of the lot.

This caused me to sprint across the lot to retrieve the vehicle:

Unfortunately, Summon was not dependable or accurate enough to use regularly. It appears Tesla might have bridged the gap needed to make it an effective feature, as two tests in parking lots proved that Summon was more responsive and faster to navigate to the location chosen.

It also did so without hesitation, confidently, and at a comfortable speed. I was able to test it twice at different distances:

I plan to test this more thoroughly and regularly through the next few weeks, and I avoided using it in a congested parking lot initially because I have not had overwhelming success with Summon in the past. I wanted to set a low baseline for it to see if it could simply pull up to the place I pinned in the Tesla app.

It was two for two, which is a big improvement because I don’t think I ever had successful Summon attempts back-to-back. It just seems more confident than ever before.

New Disengagement Categories

This is a really good idea from Tesla, but there are some issues with it. The categories you can select are Critical, Comfort, Preference, and Other.

I think the reasons why people choose to take over would be a better way to prompt drivers, like, “Traveling Too Fast,” “Incorrect Maneuver,” “Navigation Error,” would be more beneficial.

I say this because it seems that how we each categorize things might be different. For example, I shared a video of an intervention because the car had navigated to an exit to a parking lot and put its left blinker on, despite left turns not being allowed there.

I disengaged and chose Critical as the reason; it’s not a comfort issue, it’s not a preference, it’s quite literally an illegal turn, and it’s also dangerous because it cuts across several lanes of traffic and is 180 degrees.

Some said I should not have labeled this as Critical, but that’s the description I best characterized the disengagement as.

Categorizing interventions is a good thing, but it’s kind of hard to determine how to label them correctly.

Inconsistency with Regional Traffic Patterns

Tesla Full Self-Driving is pretty inconsistent with how it handles regional or local traffic patterns and road rules. The most frequent example I like to use is that of the “Except Right Turn” stop sign, which has become a notorious sighting on our social media platforms.

In the initial rollout of v14.3, my Model Y successfully navigated through one of these stop signs with no issues. However, testing at two of these stop signs yesterday proved it is still not sure how to read signs and navigate through them properly.

Off camera, I approached another one of these signs and felt the car coming to a stop, so I nudged it forward with the accelerator pedal pressed.

This helped the car go through the sign without stopping, but I could feel the bucking of the vehicle as the car really wanted to stop.

Musk said on the earnings call earlier this week that unsupervised FSD would probably be available in some regions before others, including a state-to-state basis in the U.S.

“It’s difficult to release this like to everyone everywhere all at once because we do want to make sure that they’re not unique situations in a city that particularly complex intersection or — actually, they tend to be places where people get into accidents a lot because they’re just — perhaps there’s — and like I said, an unsafe intersection or bad road markings or a lot of weather challenges. So I think we would release unsupervised gradually to the customer fleet as we feel like a particular geography is confirmed to be safe.”
This could be one of those examples that Tesla just has to figure out.

Highway Operation

Full Self-Driving is already pretty good at routine roadway navigation, so I don’t have too much to report here.

However, I was happy with FSD’s decision-making at several points, including its choice not to pass a slightly slower car and remain in the right lane as we approached the off-ramp:

Better Maneuvering at Stop Signs

Many FSD users report some strange operations at stop signs, especially four-way intersections where there is a stop sign and a line on the road, and they’re not even with one another.

I experienced this quite frequently and found that FSD would actually double stop: once at the stop sign and again at the line.

This created some interesting scenarios for me and I had many cars honk at me when the second stop would happen. Other vehicles that had waved me on to proceed through the intersection would become frustrated at the second stop.

FSD seems to have worked through this particular maneuver:

FSD should know to go to the more appropriate location (whichever provides better visibility), and proceed when it is the car’s turn to move. The double stop really ruined the flow of traffic at times and generally caused some frustration from other drivers.

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