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SpaceX’s Starship prototype proceeds at breakneck pace towards hop tests

An apparent Starship nosecone is lifted atop one of the prototype's barrel-style hull sections on December 28th. (NASASpaceflight /u/bocachicagal)

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7 years ago

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Well illustrated by recent drone photos of SpaceX’s up-and-coming Boca Chica, Texas facilities, dozens of SpaceXers and local contractors have congregated at the company’s Starship prototype work site over the last few weeks, progressing it from an empty tent and a collection of parts to a handful of large assemblies for what appears to be the first full-scale Starship hopper.

Much like Falcon 9’s Grasshopper and F9R (Reusable) hop test articles, this ungainly Starship hopper – standing an impressive 9m (29.5 ft) wide and ~40m (131 ft) tall – appears all but guaranteed to become the first integrated BFR hardware to take flight, hopefully supporting a productive series of low-altitude hop tests from a roughly-prepared South Texas pad.

https://twitter.com/austinbarnard45/status/1079402956603248641

Since SpaceX CEO Elon Musk took to Twitter to provide a number of updates on and photos of the company’s dramatically refigured approach to BFR (now Starship and Super Heavy), employees and local contractors have been working almost around the clock to keep building the first full-scale, integrated Starship test article. To be dedicated to low-speed, low-altitude hop tests, Starhopper has been a spectacle and scandal from the start thanks to an unshakable visual aesthetic reminiscent of 1950s science fiction or an elaborate and slow-burning April Fool’s prank.

SpaceX’s Starship hopper is rapidly taking form in Boca Chica, Texas. (NASASpaceflight /u/bocachicagal)

As of now, several dozen tweets and tweet replies from Musk in just the last week offer extensive support for the unorthodox new design – replacing carbon composites and an ablative heat shield for a new stainless steel alloy and liquid cooling –  while also firmly indicating that the object taking shape in South Texas really is a Starship hopper that will eventually take to the skies on a pillar of Raptor engine exhaust. Those inaugural hop tests could apparently begin as early as March or April 2019. Given Musk’s statements, it seems that this highly unusual Starship hop test program simply cannot be judged accurately by its cover, at least not easily.

Even for SpaceX, building an aerospace-grade prototype of a massive orbital spaceship outdoors – adjacent to soggy Texan marshland and Gulf of Mexico sea spray, no less – is utterly and completely unexpected, especially in an industry where rocket hardware is routinely fabricated indoors, if not in medical-grade clean rooms. The most likely explanation here is that we are seeing something more akin to the aeroshell or cocoon of a Starship hopper, with a huge amount of thought and debate ultimately landing on this oddity as the fastest, most affordable, and most data-rich path forward for full-scale BFR testing.

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In this speculative instance, the sensitive liquid methane and liquid oxygen propellant tanks – as well as Starhopper’s triple-Raptor thrust structure and spaghetti plumbing – would be fabricated in SpaceX’s Hawthorne, CA factory or McGregor, TX test facilities before being shipped to Boca Chica for integration with the large structures already in work there. Those Raptors, propellant tanks, and a general program of fit-and-finish optimizations are next on the list of significant Starhopper-related events expected to occur within the next several months.

The latter task has already begun, showing up in the form of sheet metal refinement by way of essentially stitching together loose panel gaps between and within sheet-covered sections of Starhopper’s shiny silver nose. SpaceX workers also conducted the first move of the fully-integrated hopper’s base section, previously built and then sat atop a ready-made concrete stand that may or may not have come from a water tank design. While the move was slight, the base and nose sections are now roughly side-by-side along the apron of SpaceX’s temporary tent, where a third Starhopper hull segment is being built up.

2019 is going to be wild and March/April simply cannot come soon enough.

For prompt updates, on-the-ground perspectives, and unique glimpses of SpaceX’s rocket recovery fleet check out our brand new LaunchPad and LandingZone newsletters!

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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 creates clever solution to simplify and improve its Service

Raj Jegannathan, a Vice President of IT/AI-Infra, Apps, Infosec, and Vehicle Service Operations, revealed that Tesla has started a small pilot program at a few service locations to combat this issue.

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9 hours ago

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August 7, 2025

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Credit: Tesla

Tesla has created a clever solution to simplify and improve its Service. Tesla performs most of the services that are needed on its vehicles at its company-owned Service Centers.

However, service has been a weak point of the company, as some regions have fewer Service Centers than others. This can cause long wait times for Tesla owners in some parts of the country.

There are also instances where customers do not agree with what Tesla is saying about their vehicle. In fact, one instance that revealed this new change Tesla is making to its Service was precisely that.

One owner posted on X that his vehicle’s battery seal had failed after a recall was issued. Tesla insurance and Tesla Service both did not assist, and it took CEO Elon Musk stepping in to get the issue resolved:

Another owner suggested there should be a more streamlined communications process between the customer and the Service Center, a solution that has been missing.

Raj Jegannathan, a Vice President of IT/AI-Infra, Apps, Infosec, and Vehicle Service Operations, revealed that Tesla has started a small pilot program at a few service locations to combat this issue.

Elon Musk wants Tesla Service to fix two-thirds of cars in the same day

Jegannathan said that Tesla has started to share local and regional leader contact information so customers have the ability to reach out when they have complaints or disagree with warranty claims, changes in estimates, or initial diagnostics.

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It is available in a handful of locations already, and Jegannathan said that once abuse guardrails are built, this will expand to all locations:

This would be a major improvement in the Service portion of Tesla’s business. There are common disagreements between Service and customers, specifically when Service’s suggestions don’t align with the customer’s beliefs.

When it comes to things like a warranty claim, these issues are not really up for interpretation. Instead, the repairs should be made. If there is a misunderstanding on Service’s side, a simple message from the customer could have resolved the issue. That’s basically what happened here.

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Investor's Corner

Tesla gets its best analysis from Morgan Stanley as ‘it’s all about to change’

He maintained its ‘Overweight’ rating and the $410 price target Morgan Stanley had on the stock.

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10 hours ago

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August 7, 2025

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(Credit: Tesla)

Tesla has gotten perhaps its best analysis from Morgan Stanley in quite some time, as the Wall Street firm claims that “it’s all about to change.”

That phrase could be used for both the company’s status and the world in general.

Analyst Adam Jonas said in a new note on Thursday to investors that Tesla could be one of the major winners in terms of the global transition from what it is now to what it will be.

He describes the global shift that will occur over the next few years:

“Have you interacted with a robot today? Have you even seen a robot today? No? Well, take a mental picture because it’s all about to change. When we meet someone who has never been in a Waymo or a Tesla Cybercab (which is most people), we frequently see a wince and a response such as ‘I’m not sure I’d feel comfortable getting in a car without a driver.’ We imagine going back in time to 1903 and asking people if they’d feel comfortable in an airplane.’”

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The same technological revolutions that have occurred over the past 150 years will continue to occur again and again. We are on the verge of another, Jonas believes, as companies like Tesla are working on artificial intelligence tech, which includes changing the way we look at things like transportation and labor.

Jonas includes an interesting tidbit in his note about how humanoid robots could change wages, and how it could work into the advantage of Tesla, especially as it is developing its own Optimus robot:

“We estimate 1 humanoid robot at $5/hour can do the work of 2 humans at $25/hour, generating an NPV of approximately $200k/humanoid. 1 robot shaped car can potentially drive down cost/mile of a ride share vehicle to <$0.20 mile (1/10th human-driven ride-share).”

Jonas sees Tesla as a key player in how AI will impact things like manufacturing and various automotive industries, and he believes there is long-term potential for AI, robomobility, and even autonomous eVTOL platforms.

Tesla stock: Morgan Stanley says eVTOL is calling Elon Musk for new chapter

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He maintained its ‘Overweight’ rating and the $410 price target Morgan Stanley had on the stock.

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Tesla expands Robotaxi program in Austin to new riders

Tesla has been expanding both the rider group and the geofence in Austin slowly, making sure to prioritize safety and avoid any major events with the early rollout.

Published

11 hours ago

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August 7, 2025

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Credit: @TerrapinTerpene/X

Tesla is expanding its Robotaxi program in Austin, Texas, as several people have received invitations to participate and take rides.

Tesla first launched the Robotaxi platform on June 22. It invited a handful of people to participate in the first-ever public rides. We were lucky enough to get an invitation, and our permissions have been expanded in the Bay Area pilot program as well.

The group was small and consisted of big names in the Tesla community. It expanded and is continuing to offer these exclusive invitations to notable members of the Tesla community.

There have been fewer than five subsequent invitations after the first group’s were sent in late June:

Tesla has been expanding both the rider group and the geofence in Austin slowly, making sure to prioritize safety and avoid any major events with the early rollout.

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Tesla’s new Robotaxi geofence shape is an FU by Elon Musk to the competition

“We are being very cautious. We do not want to take any chances, so we are going to go cautiously. But the service areas and the number of vehicles in operation will increase at a hyper-exponential rate,” CEO Elon Musk said during the Q2 Earnings Call.

Eventually, the Robotaxi platform will not require an invite, and it will operate without geofences. Musk believes Tesla can get there within three or six months, and plans to have at least half of the U.S. population with access to a Robotaxi by the end of the year:

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“I think we will probably have autonomous ride-hailing in probably half the population of the U.S. by the end of the year. That’s at least our goal, subject to regulatory approvals. I think we will technically be able to do it. Assuming we have regulatory approvals, it’s probably addressing half the population of the U.S. by the end of the year.”

Tesla plans to have regulatory approval in Nevada, Arizona, and Florida sooner than in other states.

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