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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.

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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 launches new Model 3 financing deal with awesome savings

Tesla is now offering a 0.99% APR financing option for all new Model 3 orders in the United States, and it applies to all loan terms of up to 72 months.

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Credit: Tesla

Tesla has launched a new Model 3 financing deal in the United States that brings awesome savings. The deal looks to move more of the company’s mass-market sedan as it is the second-most popular vehicle Tesla offers, behind its sibling, the Model Y.

Tesla is now offering a 0.99% APR financing option for all new Model 3 orders in the United States, and it applies to all loan terms of up to 72 months.

It includes three Model 3 configurations, including the Model 3 Performance. The rate applies to:

  • Model 3 Premium Rear-Wheel-Drive
  • Model 3 Premium All-Wheel-Drive
  • Model 3 Performance

The previous APR offer was 2.99%.

Tesla routinely utilizes low-interest offers to help move vehicles, especially as the rates can help get people to payments that are more comfortable with their monthly budgets. Along with other savings, like those on maintenance and gas, this is another way Tesla pushes savings to customers.

The company had offered a similar program in China on the Model 3 and Model Y vehicles, but it had ended on January 31.

The Model 3 was the second-best-selling electric vehicle in the United States in 2025, trailing only the Model Y. According to automotive data provided by Cox, Tesla sold 192,440 units last year of the all-electric sedan. The Model Y sold 357,528 units.

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Tesla hasn’t adopted Apple CarPlay yet for this shocking reason

Many Apple and iPhone users have wanted the addition, especially to utilize third-party Navigation apps like Waze, which is a popular alternative. Getting apps outside of Tesla’s Navigation to work with its Full Self-Driving suite seems to be a potential issue the company will have to work through as well.

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Credit: Michał Gapiński/YouTube

Perhaps one of the most requested features for Tesla vehicles by owners is the addition of Apple CarPlay. It sounds like the company wants to bring the popular UI to its cars, but there are a few bottlenecks preventing it from doing so.

The biggest reason why CarPlay has not made its way to Teslas yet might shock you.

According to Bloomberg‘s Mark Gurman, Tesla is still working on bringing CarPlay to its vehicles. There are two primary reasons why Tesla has not done it quite yet: App compatibility issues and, most importantly, there are incredibly low adoption rates of iOS 26.

Tesla’s Apple CarPlay ambitions are not dead, they’re still in the works

iOS 26 is Apple’s most recent software version, which was released back in September 2025. It introduced a major redesign to the overall operating system, especially its aesthetic, with the rollout of “Liquid Glass.”

However, despite the many changes and updates, Apple users have not been too keen on the iOS 26 update, and the low adoption rates have been a major sticking point for Tesla as it looks to develop a potential alternative for its in-house UI.

It was first rumored that Tesla was planning to bring CarPlay out in its cars late last year. Many Apple and iPhone users have wanted the addition, especially to utilize third-party Navigation apps like Waze, which is a popular alternative. Getting apps outside of Tesla’s Navigation to work with its Full Self-Driving suite seems to be a potential issue the company will have to work through as well.

According to the report, Tesla asked Apple to make some changes to improve compatibility between its software and Apple Maps:

“Tesla asked Apple to make engineering changes to Maps to improve compatibility. The iPhone maker agreed and implemented the adjustments in a bug fix update to iOS 26 and the latest version of CarPlay.”

Gurman also said that there were some issues with turn-by-turn guidance from Tesla’s maps app, and it did not properly sync up with Apple Maps during FSD operation. This is something that needs to be resolved before it is rolled out.

There is no listed launch date, nor has there been any coding revealed that would indicate Apple CarPlay is close to being launched within Tesla vehicles.

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Starlink restrictions are hitting Russian battlefield comms: report

The restrictions have reportedly disrupted Moscow’s drone coordination and frontline communications.

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A truckload of Starlink dishes has arrived in Ukraine. (Credit: Mykhailo Fedorov/Twitter)

SpaceX’s decision to disable unauthorized Starlink terminals in Ukraine is now being felt on the battlefield, with Ukrainian commanders reporting that Russian troops have struggled to maintain assault operations without access to the satellite network. 

The restrictions have reportedly disrupted Moscow’s drone coordination and frontline communications.

Lt. Denis Yaroslavsky, who commands a special reconnaissance unit, stated that Russian assault activity noticeably declined for several days after the shutdown. “For three to four days after the shutdown, they really reduced the assault operations,” Yaroslavsky said.

Russian units had allegedly obtained Starlink terminals through black market channels and mounted them on drones and weapons systems, despite service terms prohibiting offensive military use. Once those terminals were blocked, commanders on the Ukrainian side reported improved battlefield ratios, as noted in a New York Post report.

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A Ukrainian unit commander stated that casualty imbalances widened after the cutoff. “On any given day, depending on your scale of analysis, my sector was already achieving 20:1 (casuality rate) before the shutdown, and we are an elite unit. Regular units have no problem going 5:1 or 8:1. With Starlink down, 13:1 (casualty rate) for a regular unit is easy,” the unit commander said.

The restrictions come as Russia faces heavy challenges across multiple fronts. A late January report from the Center for Strategic and International Studies estimated that more than 1.2 million Russian troops have been killed, wounded, or gone missing since February 2022.

The Washington-based Institute for the Study of War also noted that activity from Russia’s Rubikon drone unit declined after Feb. 1, suggesting communications constraints from Starlink’s restrictions may be limiting operations. “I’m sure the Russians have (alternative options), but it takes time to maximize their implementation and this (would take) at least four to six months,” Yaroslavsky noted. 

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