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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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NASA just gave SpaceX more crew missions because Boeing can’t certify

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NASA has filed a procurement notice announcing its intent to add six post-certification missions to SpaceX’s existing Commercial Crew Transportation Capability contract. The agency said it would order up to three of those missions immediately upon adding them to the contract, with the remaining three available as needed through the end of the International Space Station’s planned operations in 2030.

The reason for the expansion is straightforward. NASA cited recently shortened ISS mission durations, technical issues and schedule delays encountered by Boeing, the allocation of missions between Boeing and SpaceX, and the ongoing technical challenges of maintaining a reliable crew transportation capability as the driving factors behind the decision. Boeing’s CST-100 Starliner has still not been certified for crewed flights, and a cargo-only Starliner mission was not included on NASA’s most recent mission manifest. With Boeing effectively sidelined for the foreseeable future, SpaceX is the only American company capable of rotating crews to the station.

SpaceX Board has set a Mars bonus for Elon Musk

The history behind this contract tells the fuller story of how SpaceX got here. NASA originally awarded SpaceX its Commercial Crew contract in 2014 for $2.6 billion. In 2022 NASA modified the contract to add five missions covering Crew-10 through Crew-14, worth $1.436 billion, bringing the total contract value at that point to $4.9 billion. The recent May 18 filing by NASA extends that runway further, with Crew-12 currently docked at the station and Crew-13 assigned and targeting a mid-September 2026 launch.

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According to a report by SpaceNews, NASA stated in its filing: “It is necessary to award additional PCMs to SpaceX given the recently shortened ISS mission durations, technical issues and schedule delays encountered by Boeing, the allocation of missions between Boeing and SpaceX, NASA’s projections for when an alternative crew transportation system may become available, and the ongoing technical challenges of maintaining a reliable capability for crewed flights to ISS.”

No dollar value for the new six missions has been publicly confirmed yet, but based on the 2022 precedent of roughly $287 million per mission, the new block could represent close to $1.7 billion in additional contract value. With SpaceX simultaneously preparing Starship as NASA’s Artemis lunar lander, filing its S-1 for a June IPO, and now absorbing more ISS crew rotation work, the company’s role as the primary contractor for American human spaceflight is no longer a matter of circumstance. It is NASA policy.

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Energy

Zuckerberg’s Meta taps Musk’s Tesla for massive clean energy project

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Credit: Tesla

In a notable intersection of Big Tech powerhouses, Meta, led by Mark Zuckerberg, has partnered with Canadian energy infrastructure giant Enbridge on a significant renewable energy initiative that will rely on battery technology from Elon Musk’s Tesla.

The project, which was announced this week, marks another step in Meta’s aggressive push to power its expanding data center operations with clean energy, dispelling many of the complaints people have about them.

This new development is located near Cheyenne, Wyoming, and will feature a 365-megawatt (MW) solar farm paired with a 200 MW/1,600 megawatt-hour (MWh) battery energy storage system, also known as BESS. Tesla is providing the batteries for the project, valued at roughly $200 million.

The story was originally reported by Utility Dive.

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This Wyoming project represents the first phase of Enbridge and Meta’s joint “Cowboy Project.” Once operational, it will deliver power to Meta’s regional data centers through Cheyenne Light, Fuel, and Power under Wyoming’s Large Power Contract Service tariff.

This tariff, originally developed in collaboration with Microsoft and Black Hills Energy, is designed specifically for large loads like data centers. It ensures that the renewable supply serves hyperscale customers without impacting retail electricity rates for other users.

The battery system will operate under a long-term tolling agreement, providing dispatchable capacity that enhances grid reliability. During periods of high demand, the utility can access the backup generation, addressing one of the key challenges of integrating large-scale renewables with the explosive growth of data center electricity demand driven by artificial intelligence.

This latest collaboration builds on prior joint efforts between Enbridge and Meta in Texas, including the 600 MW Clear Fork Solar, 152 MW Easter Wind, and 300 MW Cone Wind projects. Together with the Wyoming initiative, the companies have now partnered on roughly 1.6 gigawatts (GW) of combined solar, wind, and storage capacity.

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The deal highlights the intensifying demand for reliable, low-carbon power from technology giants. Meta has committed to supporting its data center growth with renewable energy, joining peers like Microsoft and Google in seeking large-scale solutions. Enbridge’s Allen Capps described the project as “one of the larger utility-scale battery installations supporting U.S. data center operations and growth.”

The involvement of Tesla’s battery technology adds an intriguing layer, linking two of the world’s most prominent tech leaders—Zuckerberg and Musk—in the clean energy transition.

As data centers continue to drive unprecedented electricity load growth across the United States, projects like this one illustrate how hyperscalers are turning to strategic partnerships with traditional energy players and innovative storage solutions to meet both sustainability goals and reliability needs.

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Elon Musk

SpaceX reveals reason for Starship v3 stand down, announces next launch date

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Credit: SpaceX

SpaceX has decided to stand down from what was supposed to be the first test launch of Starship’s v3 rocket tonight after a minor issue with a hydraulic pin delayed the flight once more.

The company scrubbed its first test flight of the upgraded Starship v3 on May 21 in the final minutes of the countdown. SpaceX CEO Elon Musk quickly took to social media platform X, explaining that a hydraulic pin on the launch tower’s “chopsticks” arm failed to retract properly.

Musk added that the company would fix the issue this evening. SpaceX will attempt another launch tomorrow night at 5:30 p.m. CT, 6:30 p.m. ET, and 3:30 p.m. PT.

The countdown for Starship Flight 12 — featuring the taller and more capable V3 stack with Booster 19 and Ship 39 — had been progressing smoothly until the late-stage issue surfaced. The Mechazilla tower arm, designed to secure the vehicle on the pad and eventually catch returning boosters, could not complete its retraction sequence.

SpaceX teams immediately began troubleshooting the hydraulic system for an overnight repair.

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Starship V3 introduces several significant upgrades over earlier versions. These include greater propellant capacity, more powerful Raptor 3 engines, larger grid fins, enhanced heat shielding, and an improved fuel transfer system.

We covered the changes that were announced just days ago by SpaceX:

SpaceX unveils sweeping Starship V3 upgrades ahead of May 19 launch

The changes are intended to increase payload performance, support higher flight rates, and advance the vehicle toward operational missions, including Starlink deployments, NASA Artemis lunar landings, and future crewed Mars flights. The debut flight from Starbase’s new Launch Pad 2 marked an important milestone in scaling up the fully reusable Starship system.

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This stand-down highlights the intricate challenges of preparing the world’s most powerful rocket for flight. Despite extensive pre-launch checks, a single component in the ground support equipment can force a scrub.

The incident aligns with Starship’s proven iterative development approach. Previous test flights have encountered both successes and setbacks, each providing critical data that refines hardware and procedures. Some outlets may call some of these flights “failures,” when in reality, they are all opportunities for SpaceX to learn for the next attempt.

With V3, SpaceX aims to reduce ground-system dependencies and increase launch cadence to meet ambitious long-term goals.

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