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SpaceX fits Starship prototype with tank bulkheads as hop test pad progresses

Starhopper and SpaceX's spartan assembly facilities are pictured here, showing the inside of the aft section and a completed tank dome. (Austin Barnard)

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SpaceX workers have begun installing fuel and oxidizer tank bulkheads inside the first BFS/Starship prototype at the same time as the vehicle’s nearby ‘launch’ facility continues to sprout important infrastructure and slowly morph from a giant pile of dirt into something capable of supporting rocket hop tests.

Several observable characteristics of this project still do not immediately make sense but whatever the direction SpaceX is moving in, engineers and technicians are working around the clock to ensure that progress is steady.

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Moreso than any other single part, the most confusing aspect of Starhopper has to be the apparent condition of its steel tank domes, distinctly covered with a patina of impurities like rust, dirt, dust, and grime. For a water tower or other miscellaneous storage tank, this would be completely acceptable. For aerospace-grade propellant tanks that will have to safely store dozens or even hundreds of tons of supercool liquid methane and oxygen to feed ultra-high-performance Raptor engines, the purity of ingested propellant and thus the cleanliness of the tanks holding it is going to be of paramount importance.

To use an example that applies to the rockets SpaceX currently flies, Falcon 9’s first and second stages are almost always drained and cleaned before and after their first static fire tests in McGregor, Texas to ensure that no unintended debris is ingested by Merlin turbopumps. This is necessary because Falcon rockets are currently built in an extremely large hangar that simply cannot feasibly be kept to cleanroom conditions, while SpaceX’s garment requirements are less strict than some old-guard aerospace companies, typically letting workers wear normal clothes (albeit with hairnets/beardnets) while working inside Falcon 9 tanks and structures. The improved work conditions and worker comfort comes at the cost of frequent tank cleaning.

 

While SpaceX clearly has a great deal of experience with nontraditional methods of rocket production, the Hawthorne assembly line might be the cleanest cleanroom on Earth compared to Starhopper’s rusty tank domes and fully-outdoors assembly. Even odder is the apparent fact that SpaceX is actually installing (and maybe even welding) those tank domes without any cleaning at all, indicating that they either look far worse than they actually are, are not a real problem for Raptor or cryogenic propellant tanks, or will be scoured only after installation. Regardless, SpaceX is keeping close followers and those familiar with aerospace on the tips of their toes as Starhopper continues to be worked on.

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(Launch) pad progress

Roughly one mile to the east of Starhopper’s assembly roost, SpaceX employees and contractors have been working to complete earthmoving and start outfitting a prospective Starhopper prototype launch pad with a stable concrete base and all the infrastructure needed to support a complex rocket and its propellant, electricity, and heat-resistant surface needs. However, despite recent statements from executives like CEO Elon Musk and COO/President Gwynne Shotwell, the ‘facility’ appears to be many, many months away from anything reminiscent of an actual launch pad like the three SpaceX currently operates in California and Florida.

Instead, it seems that the first BFR-related launch facility will be more of a Spartan, minimalist slab of concrete, a healthy berm, and a handful of propellant tanks and heat exchangers, much like the ‘pad’ that supported Falcon 9’s Grasshopper and F9R hoppers. Over the last few days, the pad construction crew has installed the first of those propellant tanks and heat exchangers and continue to refine the overall layout of the site, still primarily made of compacted dirt. Given the potential simplicity of a Grasshopper-style launch and landing pad, the facility could be anywhere from a few weeks to a few months away from completion.

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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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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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Tesla Korea hiring AI Chip Engineers amid push for high-volume AI chips

Tesla Korea stated that it is seeking “talented individuals to join in developing the world’s highest-level mass-produced AI chips.”

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Credit: xAI/X

In a recent post on X, Tesla Korea announced that it is hiring AI Chip Design Engineers as part of a project aimed at developing what the company describes as the world’s highest-volume AI chips. CEO Elon Musk later amplified the initiative.

Tesla Korea stated that it is seeking “talented individuals to join in developing the world’s highest-level mass-produced AI chips.”

“This project aims to develop AI chip architecture that will achieve the highest production volume in the world in the future,” Tesla Korea wrote in its post on X.

As per Tesla Korea, those who wish to apply for the AI Chip Design Engineer post should email Ai_Chips@Tesla.com and include “the three most challenging technical problems you have solved.”

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Elon Musk echoed the hiring push in a separate post. “If you’re in Korea and want to work on chip design, fabrication or AI software, join Tesla!” he wrote.

The recruitment effort in South Korea comes as Tesla accelerates development of its in-house AI chips, which power its Full Self-Driving (FSD) system, Optimus humanoid robot, and data center training infrastructure.

Tesla has been steadily expanding its silicon development teams globally. In recent months, the company has posted roles in Austin and Palo Alto for silicon module process engineers across lithography, etching, and other chip fabrication disciplines, as noted in a Benzinga report.

Tesla Korea’s hiring efforts align with the company’s long-term goal of designing and producing AI chips at massive scale. Musk has previously stated that Tesla’s future AI chips could become the highest-volume AI processors in the world.

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The move also comes amid Tesla’s broader expansion into AI initiatives. The company recently committed about $2 billion into xAI as part of a Series E funding round, reinforcing its focus on artificial intelligence across vehicles, robotics, and compute infrastructure.

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SpaceX and xAI tapped by Pentagon for autonomous drone contest

The six-month competition was launched in January and is said to carry a $100 million award.

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Credit: SpaceX/X

SpaceX and its AI subsidiary xAI are reportedly competing in a new Pentagon prize challenge focused on autonomous drone swarming technology, as per a report from Bloomberg News

The six-month competition was launched in January and is said to carry a $100 million award.

Bloomberg reported that SpaceX and xAI are among a select group invited to participate in the Defense Department’s effort to develop advanced drone swarming capabilities. The goal is reportedly to create systems that can translate voice commands into digital instructions and manage fleets of autonomous drones.

Neither SpaceX, xAI, nor the Pentagon’s Defense Innovation Unit has commented on the report, and Reuters said it could not independently verify the details.

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The development follows SpaceX’s recent acquisition of xAI, which pushed the valuation of the combined companies to an impressive $1.25 trillion. The reported competition comes as SpaceX prepares for a potential initial public offering later this year.

The Pentagon has been moving to speed up drone deployment and expand domestic manufacturing capacity, while also seeking tools to counter unauthorized drone activity around airports and major public events. Large-scale gatherings scheduled this year, including the FIFA World Cup and America250 celebrations, have heightened focus on aerial security.

The reported challenge aligns with broader Defense Department investments in artificial intelligence. Last year, OpenAI, Google, Anthropic, and xAI secured Pentagon contracts worth up to $200 million each to advance AI capabilities across defense applications.

Elon Musk previously joined AI and robotics researchers in signing a 2015 open letter calling for a ban on offensive autonomous weapons. In recent years, however, Musk has spoken on X about the strengths of drone technologies in combat situations.

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