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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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Tesla Model S completes first ever FSD Cannonball Run with zero interventions

The coast-to-coast drive marked the first time Tesla’s FSD system completed the iconic, 3,000-mile route end to end with no interventions.

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A Tesla Model S has completed the first-ever full Cannonball Run using Full Self-Driving (FSD), traveling from Los Angeles to New York with zero interventions. The coast-to-coast drive marked the first time Tesla’s FSD system completed the iconic, 3,000-mile route end to end, fulfilling a long-discussed benchmark for autonomy.

A full FSD Cannonball Run

As per a report from The Drive, a 2024 Tesla Model S with AI4 and FSD v14.2.2.3 completed the 3,081-mile trip from Redondo Beach in Los Angeles to midtown Manhattan in New York City. The drive was completed by Alex Roy, a former automotive journalist and investor, along with a small team of autonomy experts.

Roy said FSD handled all driving tasks for the entirety of the route, including highway cruising, lane changes, navigation, and adverse weather conditions. The trip took a total of 58 hours and 22 minutes at an average speed of 64 mph, and about 10 hours were spent charging the vehicle. In later comments, Roy noted that he and his team cleaned out the Model S’ cameras during their stops to keep FSD’s performance optimal. 

History made

The historic trip was quite impressive, considering that the journey was in the middle of winter. This meant that FSD didn’t just deal with other cars on the road. The vehicle also had to handle extreme cold, snow, ice, slush, and rain. 

As per Roy in a post on X, FSD performed so well during the trip that the journey would have been completed faster if the Model S did not have people onboard. “Elon Musk was right. Once an autonomous vehicle is mature, most human input is error. A comedy of human errors added hours and hundreds of miles, but FSD stunned us with its consistent and comfortable behavior,” Roy wrote in a post on X.

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Roy’s comments are quite notable as he has previously attempted Cannonball Runs using FSD on December 2024 and February 2025. Neither were zero intervention drives.

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Tesla removes Autopilot as standard, receives criticism online

The move leaves only Traffic Aware Cruise Control as standard equipment on new Tesla orders.

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Credit: Tesla Malaysia/X

Tesla removed its basic Autopilot package as a standard feature in the United States. The move leaves only Traffic Aware Cruise Control as standard equipment on new Tesla orders, and shifts the company’s strategy towards paid Full Self-Driving subscriptions.

Tesla removes Autopilot

As per observations from the electric vehicle community on social media, Tesla no longer lists Autopilot as standard in its vehicles in the U.S. This suggests that features such as lane-centering and Autosteer have been removed as standard equipment. Previously, most Tesla vehicles came with Autopilot by default, which offers Traffic-Aware Cruise Control and Autosteer.

The change resulted in backlash from some Tesla owners and EV observers, particularly as competing automakers, including mainstream players like Toyota, offer features like lane-centering as standard on many models, including budget vehicles.

That being said, the removal of Autopilot suggests that Tesla is concentrating its autonomy roadmap around FSD subscriptions rather than bundled driver-assistance features. It would be interesting to see how Tesla manages its vehicles’ standard safety features, as it seems out of character for Tesla to make its cars less safe over time. 

Musk announces FSD price increases

Following the Autopilot changes, Elon Musk stated on X that Tesla is planning to raise subscription prices for FSD as its capabilities improve. In a post on X, Musk stated that the current $99-per-month price for supervised FSD would increase over time, especially as the system itself becomes more robust.

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“I should also mention that the $99/month for supervised FSD will rise as FSD’s capabilities improve. The massive value jump is when you can be on your phone or sleeping for the entire ride (Unsupervised FSD),” Musk wrote. 

At the time of his recent post, Tesla still offers FSD as a one-time purchase for $8,000, but Elon Musk has confirmed that this option will be discontinued on February 14, leaving subscriptions as the only way to access the system.

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Tesla begins Cybertruck deliveries in a new region for the first time

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Credit: @derek1ee | X

Tesla has initiated Cybertruck deliveries in a new region for the first time, as the all-electric pickup has officially made its way to the United Arab Emirates, marking the newest territory to receive the polarizing truck.

Tesla launched orders for the Cybertruck in the Middle East back in September 2025, just months after the company confirmed that it planned to launch the pickup in the region, which happened in April.

I took a Tesla Cybertruck weekend Demo Drive – Here’s what I learned

By early October, Tesla launched the Cybertruck configurator in the United Arab Emirates, Qatar, and Saudi Arabia, with pricing starting at around AED 404,900, or about $110,000 for the Dual Motor configuration.

This decision positioned the Gulf states as key early international markets, and Tesla was hoping to get the Cybertruck outside of North America for the first time, as it has still been tough to launch in other popular EV markets, like Europe and Asia.

By late 2025, Tesla had pushed delivery timelines slightly and aimed for an early 2026 delivery launch in the Middle East. The first official customer deliveries started this month, and a notable handover event occurred in Dubai’s Al Marmoom desert area, featuring a light and fire show.

Around 63 Cybertrucks made their way to customers during the event:

As of this month, the Cybertruck still remains available for configuration on Tesla’s websites for the UAE, Saudi Arabia, Qatar, and other Middle Eastern countries like Jordan and Israel. Deliveries are rolling out progressively, with the UAE leading as the first to see hands-on customer events.

In other markets, most notably Europe, there are still plenty of regulatory hurdles that Tesla is hoping to work through, but they may never be resolved. The issues come from the unique design features that conflict with the European Union’s (EU) stringent safety standards.

These standards include pedestrian protection regulations, which require vehicles to minimize injury risks in collisions. However, the Cybertruck features sharp edges and an ultra-hard stainless steel exoskeleton, and its rigid structure is seen as non-compliant with the EU’s list of preferred designs.

The vehicle’s gross weight is also above the 3.5-tonne threshold for standard vehicles, which has prompted Tesla to consider a more compact design. However, the company’s focus on autonomy and Robotaxi has likely pushed that out of the realm of possibility.

For now, Tesla will work with the governments that want it to succeed in their region, and the Middle East has been a great partner to the company with the launch of the Cybertruck.

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