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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 Robotaxi just got a big benefit from the U.S. government

The NHTSA is looking to help streamline the application process for companies developing driverless vehicles.

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Credit: Tesla

Tesla Robotaxi just got a big benefit from the U.S. Government, as the National Highway Traffic Safety Administration (NHTSA) is looking to ease some rules and streamline the application process that could hinder the development and licensing of autonomous vehicles.

Tesla is set to launch its Robotaxi platform in the coming days or weeks, but regulation on autonomous vehicles is incredibly slim, so automakers are left in a strange limbo as permissions to operate are usually up to local jurisdictions.

The NHTSA still has the ultimate say, but it is now adopting a new strategy that will see companies gain an exemption from federal safety standards and streamline the entire application process.

The agency is authorized to grant exemptions to permit manufacturers to produce vehicles over a two or three-year period that might not comply with certain Federal Motor Vehicle Safety Standards (FMVSS). Robotaxi, for example, will eventually not have a steering wheel or pedals, through the Cybercab that Tesla unveiled last October.

The exemption program the NHTSA announced today would be possible through Part 555 of the National Traffic and Motor Vehicle Safety Act:

“NHTSA may grant a Part 555 exemption if at least one of four bases listed in the statute is met and NHTSA determines that the exemption is consistent with the public interest and the Safety Act. The statute also authorizes NHTSA to subject an exemption to terms the agency deems appropriate and requires that NHTSA publish notice of the application and provide an opportunity to comment.”

The rapid and non-stop innovation that is being performed is tough to keep up with from a legal standpoint. The NHTSA recognizes this and says current legislation is appropriate for traditional vehicles, but not for the self-driving cars companies are producing now:

“The current Part 555 process was designed for traditional vehicles. As currently applied, this process is not well suited for processing exemptions involving ADS-equipped vehicles in a timely manner or overseeing the unique complexities involving their operations. This has resulted in long processing times for applications for ADS-equipped vehicles. NHTSA must improve its Part 555 processing times substantially to keep pace with the rapid innovation of the ADS industry and to ensure that exemptions remain effective tools for nurturing groundbreaking safety technologies.”

Now, the NHTSA will be “enhancing application instructions” to help manufacturers understand the requirements involved in the application process. This will streamline the entire process by “reducing the need for NHTSA to request additional information from the manufacturer,” the agency says.

First Tesla driverless robotaxi spotted in the wild in Austin, TX

Next, the NHTSA is going to have a more flexible approach to evaluating exemptions for ADS-equipped vehicles:

“To build flexibility into the Part 555 process while also accounting for the unique aspects of those exemptions, NHTSA intends to develop terms that could be included in Part 555 exemption grants, when appropriate, to condition operations of exempted ADS-equipped vehicles on enhanced and continuing oversight from NHTSA. NHTSA would expect to administer this enhanced oversight through letters, which could be updated over time, mirroring real-world ADS development. This will enable NHTSA to focus its initial review during the application stage and align the Part 555 oversight approach more closely to exemptions administered under NHTSA’s Automated Vehicle Exemption Program (AVEP), which have proven effective for ADS.”

This will benefit any company making autonomous vehicles, but it will especially benefit Tesla in the short-term as it is readying for the launch of Robotaxi.

Tesla is trading up 1.89 percent at the time of publication.

Part 555 Letter June 2025 by Joey Klender on Scribd

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SpaceX produces its 10 millionth Starlink kit

The first 5 million Starlink kits took nearly four years to build.

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Credit: Starlink/X

SpaceX has achieved a major milestone, producing its 10 millionth Starlink kit. The accomplishment was celebrated across the company’s Hawthorne, California, and Bastrop, Texas, facilities. 

The milestone was shared in social media by Sujay Soman, Senior Facilities Engineer, in a LinkedIn post, which has since been deleted. 

Starlink Production Ramp

Soman noted in his LinkedIn post that the first 5 million Starlink kits took nearly four years to build, but the next 5 million kits were completed in just 11 months. This underscores SpaceX’s intense efforts to ramp up the satellite internet system’s production, and it reflects the private space company’s manufacturing prowess.

The SpaceX Senior Facilities Engineer shared a couple of photos of the Machine Maintenance and Facilities team in Bastrop to commemorate the event.

“Today, Starlink Product teams across our Hawthorne and Bastrop sites produced the 10th Million Starlink Kit! It took almost 4 years to build our first 5 million kits, and we doubled that in about 11 months. Monumental accomplishment!” Soman wrote in his post.

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Credit: Sujay Soman/LinkedIn

World-Changing Technology 

The Starlink kits, featuring dish hardware and supporting equipment, enable users to connect to the company’s growing constellation of low Earth orbit satellites. With over 6,000 satellites launched to date, Starlink now provides fast and reliable internet connectivity to over 6 million customers worldwide. This was a significant increase from the 5 million customers that the company reported in February 2025.

SpaceX has not detailed its next production targets, but the production of Starlink’s 10 millionth kit milestone signals the company’s readiness to scale further. Being an Elon Musk-led company, SpaceX is arguably the best in the business when it comes to efficient and cost-effective manufacturing. It would then be unsurprising if SpaceX announces another Starlink production milestone soon.

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Tesla retires yoke steering wheel in base Model S and X

Tesla’s controversial steering yoke is now exclusive to the Model S and Model X Plaid.

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tesla-model-s-plaid-yoke
Credit: @dkrasniy/X

Tesla has closed a chapter in the saga of the Model S and Model X’s controversial steering yoke. Following the announcement of the new iterations of the flagship vehicles, Tesla promptly removed the steering option for the vehicles’ base variants.

This means that if drivers wish to experience the Model S or Model X with a yoke, they would have to go Plaid.

The new Model S and Model X

The refresh of the Model S and Model X were quite minor, with the two vehicles featuring a new front camera, a new color, and a handful of other small changes like new exterior styling for the Model S Plaid. Tesla also noted on its website that the two vehicles now have a much smoother and quieter ride.

The changes were quite polarizing, with some appreciating the subtle improvements made to the two flagship cars and others arguing that Tesla should have done more. Others, however, noted that the level of improvements implemented on the Model S and Model X would already be considered major refresh for a tech company like Apple.

No More Yoke Unless Plaid

When Tesla refreshed the Model S and Model X in 2021, the vehicles were released with a steering yoke as standard. The yoke was controversial, with critics stating that it was unsafe and fans stating that it made driving the Model S and Model X fun. Tesla later introduced a round steering wheel option for the Model S and Model X, which later became standard on the two flagship vehicles.

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This remains true today, with the most recent versions of the Model S and Model X still being released with a round steering wheel as standard. Those who wish to experience the Model S and Model X Plaid as envisioned by the company and its CEO, Elon Musk, however, might find it a good idea to spend the extra $1,000 for the vehicles’ yoke steering wheel.

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