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SpaceX installs orbital Starship heat shield prototype with robots
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.
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 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.
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”.
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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Elon Musk
Elon Musk reveals when SpaceX will perform first-ever Starship catch
“Starship catch is probably flight 13 to 15, depending on how well V3 flights go,” Musk said.
Elon Musk revealed when SpaceX would perform the first-ever catch attempt of Starship, its massive rocket that will one day take life to other planets.
On Tuesday, Starship aced its tenth test flight as SpaceX was able to complete each of its mission objectives, including a splashdown of the Super Heavy Booster in the Gulf, the deployment of eight Starlink simulators, and another splashdown of the ship in the Indian Ocean.
It was the first launch that featured a payload deployment:
SpaceX Starship Flight 10 was so successful, it’s breaking the anti-Musk narrative
SpaceX was transparent that it would not attempt to catch the Super Heavy Booster, something it has done on three previous occasions: Flight 5 on October 13, 2024, Flight 7 on January 16, and Flight 8 on March 6.
This time, it was not attempting to do so. However, there are bigger plans for the future, and Musk detailed them in a recent post on X, where he discussed SpaceX’s plans to catch Starship, which would be a monumental accomplishment.
Musk said the most likely opportunities for SpaceX to catch Starship itself would be Flight 13, Flight 14, and Flight 15, but it depends on “how well the V3 flights go.”
The Starship launched with Flight 10 was a V2, which is the same size as the subsequent V3 rocket but has a smaller payload-to-orbit rating and is less powerful in terms of initial thrust and booster thrust. Musk said there is only one more V2 rocket left to launch.
Starship catch is probably flight 13 to 15, depending on how well V3 flights go
— Elon Musk (@elonmusk) August 27, 2025
V3 will be the version flown through 2026, as V4, which will be the most capable Starship build SpaceX manufactures, is likely to be the first company ship to carry humans to space.
Musk said that SpaceX planned to “hopefully” attempt a catch of Starship in 2025. However, it appears that this will likely be pushed back to 2026 due to timing.
SpaceX will take Starship catch one step further very soon, Elon Musk confirms
SpaceX would need to launch the 11th and 12th test flights by the end of the year in order to get to Musk’s expected first catch attempt of Flight 13. It’s not unheard of, but the company will need to accelerate its launch rate as it has only had three test flights this year.
News
Tesla Robotaxi rival Waymo confirms massive fleet expansion in Bay Area
New data from the California Public Utilities Commission (CPUC) said Waymo had 1,429 vehicles operating in California, and 875 of them were “associated with a terminal in San Francisco,” according to The SF Examiner.
Tesla Robotaxi rival Waymo has confirmed that it has expanded its fleet of driverless ride-sharing vehicles in the Bay Area of California massively since its last public disclosure.
It is perhaps one of the most important metrics in the race for autonomous supremacy, along with overall service area. Tesla has seemed to focus on the latter, while expanding its fleet slowly to maintain safety.
Waymo, on the other hand, is bringing its fleet size across the country to significant levels. In March, it told The SF Examiner that there were over 300 Waymos in service in the San Francisco area, which was not a significant increase from the 250 vehicles on the road it reported in August 2023.
In May, the company said in a press release that it had more than 1,500 self-driving Waymos operating nationwide. More than 600 were in the San Francisco area.
Tesla analyst compares Robotaxi to Waymo: ‘The contrast was clear’
However, new data from the California Public Utilities Commission (CPUC) said Waymo had 1,429 vehicles operating in California, and 875 of them were “associated with a terminal in San Francisco,” according to The SF Examiner.
CPUC data from March 2025 indicated that there were a total of 1,087 Waymo vehicles in California, with 762 located in San Francisco. Some were test vehicles, others were deployed to operate as ride-sharing vehicles.
The company’s August update also said that it deploys more than 2,000 commercial vehicles in the United States. That number was 1,500 in May. There are also roughly 400 in Phoenix and 500 in Los Angeles.
While Waymo has done a good job of expanding its fleet, it has also been able to expand its footprint in the various cities it is operating in.
Most recently, it grew its geofence in Austin, Texas, to 90 square miles. This outpaced Tesla for a short period before the company expanded its Robotaxi service area earlier this week to roughly 170 square miles.
Tesla one-ups Waymo once again with latest Robotaxi expansion in Austin
The two companies have drastically different approaches to self-driving, as Waymo utilizes LiDAR, while Tesla relies solely on cameras for its suite. Tesla CEO Elon Musk has made no mistake about which he believes to be the superior solution to autonomy.
News
Tesla launches Full Self-Driving in a new region
Today, Tesla launched Full Self-Driving in Australia for purchase by car buyers for $10,100, according to Aussie automotive blog Man of Many, which tried out the suite earlier this week.
Tesla has launched its Full Self-Driving suite in a new region, marking a significant step in the company’s progress to expand its driver assistance suite on a global scale.
It is also the first time Tesla has launched FSD in a right-hand-drive market.
Today, Tesla launched Full Self-Driving in Australia for purchase by car buyers for $10,100, according to Aussie automotive blog Man of Many, which tried out the suite earlier this week.
Previously, Basic and Enhanced Autopilot suites were available, but the FSD capability now adds Traffic Light and Stop Sign Control, along with all the features of the previous two Autopilot suites.
🚨 Tesla has officially launched Full Self-Driving in Australia for the price of $10,100 outright.
The move marks a significant step in Tesla’s progress to expand the suite on a global scale pic.twitter.com/zzHa8Ngqls
— TESLARATI (@Teslarati) August 28, 2025
It is the first time Tesla has launched the suite by name in a region outside of North America. In China, Tesla has “City Autopilot,” as it was not permitted to use the Full Self-Driving label for regulatory reasons.
However, Tesla still lists Full Self-Driving (Supervised) as available in the U.S., Canada, China, Mexico, and Puerto Rico.
The company teased the launch of the suite in Australia earlier this week, and it appeared to have been released to select media members in the region earlier this week:
Tesla FSD upcoming Australia release seemingly teased bv media
The rollout of Full Self-Driving in the Australian market will occur in stages, as Model 3 and Model Y vehicles with Hardware 4 will receive the first batch of FSD rollouts in the region.
TechAU also reported that “the initial deployment of FSDs in Australia will roll out to a select number of people outside the company, these people are being invited into Tesla’s Early Access Program.”
Additionally, the company reportedly said it is “very close” to unlocking FSD in customer cars:
BREAKING: Tesla has officially announced that FSD (Supervised) is launching in Australia, marking a huge milestone for the company.
The rollout will happen in stages. HW4 Model 3s and Model Ys will get it first. Tesla says it is “very close” to being unlocked in customer cars.… pic.twitter.com/r1dYnFRa6o
— Sawyer Merritt (@SawyerMerritt) August 28, 2025
Each new Tesla sold will also come with a 30-day free trial of the suite.
Australia is the sixth country to officially have Full Self-Driving available to them, following the United States, Canada, China, Mexico, and Puerto Rico.
Here’s the first look at the suite operating in Australia:
Elon Musk reveals when SpaceX will perform first-ever Starship catch
Tesla Robotaxi rival Waymo confirms massive fleet expansion in Bay Area
Tesla launches Full Self-Driving in a new region
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